I designed the gears in Adobe Illustrator, based on historical gear photos on Google Images. (Rotate with Copy is very helpful when drawing gears!) Then I cut the gears from cardboard shipping boxes on an Epilog Helix 60 Watt laser cutter.I also designed and cut a frame from MDF in the form of a toothed wheel to support the gears, because I hadn’t made anything this large before and wanted it to be sturdy. It was larger than the 18″ dimension of the laser cutter, so I had to split it in two parts and assemble it later.To get the variety of shiny metal finishes shown, I painted both sides of the cardboard gears with two coats of red rattle can primer, then two coats of metallic paint from my local home improvement centers.
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