Bevel Gear

ver. 1.02

The bevel gear changes the direction of a turning movement. This working paper mechanism gives you all the parts you need as well as clearly illustrated instructions to make your own bevel gear mechanism. Let the turning begin.
Rob Ives / Flying Pig 2005 www.flying-pig.co.uk

Instructions
You will need a craft knife or other sharp knife, a pair of scissors, some glue and a glue spreader. The best type of glue to use is white school glue (PVA.) First of all print out all of the parts sheets onto thin cardboard. Photocopier card is ideal. Leave the ink to dry completely before continuing. Before cutting anything out, score along all the dotted lines and cut out any holes with a craft knife. Both these jobs are easier to do on full sheets of card. Dashed lines are hill folds, dotted lines are valley folds. Cut along the solid lines. Grey areas show where to glue. Dashed lines are hill folds Dotted lines are valley folds

Cut out

Black lines show where to cut.

Shaded areas show where to glue.

1
Both gears are constructed in the same way. Start off by cutting out the gear former and the teeth. Glue the teeth to the former, use the coloured lines for alignment, line up the coloured line on the teeth with the line on the former. The sixteen tooth gear uses red lines and dots, the eleven tooth gear uses blue lines and dots.

2
Fold the gear former round and glue it together so that the teeth butt up against each other. Fit the gear top into place from the back of the gear. Dont glue the gear base in yet. Repeat this process for the second gear.

Bevel Gear Instructions 1

Sixteen tooth gear (Red) Assemble the shaft. Slide the washer into place and glue down the tabs. Glue the gear base into place on the shaft.

Slide the previously assembled sixteen tooth gear (red) into place and glue the flaps top and bottom. Make sure the gear is straight on the shaft!

6
Glue together the box top as shown in the picture left.

Repeat the same process for the eleven tooth gear (blue). Notice that this gear is effectively upside down compared to the red gear.

Glue together the box base as shown in the picture on the right.

7
Assemble the handle in three steps. Glue the two square sections as shown. Fold the two square sections into each other and glue. Fold the long flap round and glue into place.

Bevel Gear Instructions 2

8
Turn the box upside down. Thread the sixteen tooth gear (red) down through the hole in the top of the box. Fit the eleven tooth gear (blue) into the box through the two holes in the side of the box. Use the grey area on the blue shaft to show where to fit the shaft washers. Glue the base of the box into place on the bottom of the box.

Washer

...and finally. Thread the box upper down over the vertical shaft and glue it into place on the box. Glue the handle to the horizontal shaft using the grey areas for alignment. Assemble the two vanes and glue them to the vertical shaft. the bevel gear should now be ready to go!

Bevel Gear Instructions 3

Washers

Cut out

Box

Cut out

Cut out

Cut out

Bevel Gear Parts 1

Rob Ives / Flying Pig 2005 www.flying-pig.co.uk

Rob Ives / Flying Pig 2005 www.flying-pig.co.uk

Handle

Sixteen Tooth Gear Bottom

Sixteen Tooth Gear Top

Eleven Tooth Gear Top

Bevel Gear Parts 2

Eleven Tooth Gear Bottom Box Top

Box Bottom

Vanes

Sixteen Tooth Gear Former

Eleven Tooth Gear Former

Sixteen Tooth Gear Teeth

Bevel Gear Parts 3

Eleven Tooth Gear Teeth

Box Upper

Cut out

Eleven Tooth Gear Shaft

Sixteen Tooth Gear Shaft

Bevel Gear Parts 4