thanks for joining me for part two of my wooden cog video in the first part i made the inner section which was basically a wheel in this part i'll make the outer rim and then i'll make the teeth and fit those and finish it i won't go over my process for milling the wood as i show plenty of that in part one and i've also showed it many times in my past videos i'm tilting the saw blade over six degrees ready to cut segments for the outer ring first i'll cut off one end of all the pieces when i've done that i set the stop and cut 30 pieces which is what i need to make the ring i'm doing a quick test fit to make sure the angles are correct and i get a good fit it's difficult to see just placing them there so i'll run some tape around to hold them and they look just about spot on so i'll get on with gluing them up it doesn't need any clamps as the tape pulls it together plenty tight enough i've made the ring slightly too big i did leave a couple of millimeters extra and in hindsight i should have left more it really is only just too big and i could have maybe just gone with it but instead i've decided to cut the ring in five places and when i rejoin them i'll place those joins where the spokes meet the rim and keep it all even the thickness of the blade kerf over the five cuts will remove just enough material to reduce the diameter of the ring if it's okay with you i'm going to sponsor my own video just like i did in part one if you're looking for some woodworking projects to put your hand to and to start building some of my most popular projects simply click the link in the description below and for just the next 72 hours i've bundled five of my top woodworking plans for over 50 percent off inside the bundle you'll get access to my bedside table plans mini workbench folding desk solid workbench and my stylish plywood desk so simply click the link in the description below before the 72 hour sale is up there's not long left so if you're interested you should get in there now and as always thanks for your support i'll use a router and a circle cutting jig to make the segmented ring round but to do that i need a center point to rotate the jig around i've screwed these battens down to my workbench and a dab of hot glue on the ends will stop the ring from moving now i'm finding the center point with
a compass it's barely big enough but with a pencil fully extended it just about works i may make a big compass in the future and make a video if that's something you'd like to see and i run the compass around from the point to double check that it's in the right place i'm making one pass and then setting the stop on the router to go five millimeters deeper and then make another pass and keep doing that until the router hits its limit of depth that's the inside done i'll move the pin on the jig and route the outside of the ring i was pushing here to get this done before the end of the day and i didn't even realize until i saw the footage but i've been routing the outside in the wrong direction it was cutting very well though and it wasn't a problem to remove the rest of it i'll use a pattern following bit on the router table and i could only just about get it all with the longest bit that i have it's not perfect but will clean up easy enough with a bit of sanding the ring is a bit of a loose fit with the wheel section there's a millimeter gap all the way around which isn't too bad as i can glue it with construction adhesive i'll clamp it in position first and while i was doing that i had the great pleasure of a visit from someone many of you will know love what you're doing here neil but i really think you should have made this out of metal i think welding and sparks would have made this job a lot better but i think the clamp can probably go on here there you go how's that Scott's a fellow maker on youtube his channel is Forme Industrious he makes awesome stuff he's super creative and we'll hopefully do a collaboration video sometime soon for those who don't know him i'll put a link in the description anyway the reason i clamped it together in position was to place some masking tape in the hope of avoiding the construction adhesive getting all over the place next i'll take out the screws that i just fixed into the end of each spoke i'll add some glue and then i'll put it back together again the tape did its job and it limited the amount of spread i then ran another bead of glue around and then cleaned it up with some turps i reckon that's looking great and starting to look a lot more substantial now i'll start the teeth and to make those i've prepared this stock off camera i milled three sides and now i'll cut this profile into each piece first i'll cut a bevel off each side and then i'll router groove along the bottom i'm cutting the teeth to length and i'm doing that slightly longer than the width of the rim that they'll be fixed to and there's 65 of them to attach the teeth i'll be using splines and i prepared this stock off camera and here i'm cutting them into individual pieces i've already got the grooves for the splines cut in the teeth now i need to cut grooves around the outside of the outer rim i'm going to work in sections going from spoke to spoke after measuring the distance around the outside between the spokes i'll divide that by the number of teeth to get me in the ballpark i've set that measurement on some calipers and after pushing them into a piece of scrap i'll set some dividers from the indents i'm setting them out lightly first just to see how close they land on the spokes it's a little over so i made adjustments and then checked again it took a few times until i got them perfect i then used the divots made by the dividers to mark across the rim before i route the grooves i'll remove the screws i wouldn't want to hit those but i will put them back in later on and to route the grooves i've made this saddle jig which doesn't need explaining as it really is quite simple i'm just eyeballing the center of the jig to the marks and because i need to route the groove at three different depths i've made this block to help set the router quickly the project is just a piece of art for display although i would actually like to make a cast of it i have no idea about pattern making and certainly don't claim to i'm just having fun creating something cool i realize i'd need to add fillets in the corners if it did get casted but i didn't realize and it was brought to my attention any straight sides would need a draft angle on them basically a taper to allow it to come out of the mold anyway if anyone thinks that they could help with casting it i'd love to hear from you i marked out each section separately to make sure that the teeth didn't go too far astray i didn't want to get all the way around to where i started and end up with half a gap for the last tooth that took a good couple of hours to cut all those and now i'll glue the teeth in because i was wetting the area around the next tooth when wiping off the excess glue i glued every other one and then went back around and filled in the rest afterwards i was struggling a little with this setup so i stood the cog upright and use the smaller brush so i wasn't getting in quite as much of a mess and this worked out much better i reckon the teeth have really pulled it together and i think it looks amazing next i can start sanding and there's lots of it the belt sander did a great job of sanding the slightly oversized teeth down to the rim and then i used the detail sander to get in between the teeth and over the whole thing getting into all the corners i was very unsure what to finish it
with i even thought about painting it in the end i went for hard wax oil i put two coats on sanding over the whole thing between the coats and even though i haven't shown it here i did a bit of filling here and there too i made a simple bracket off camera and for now i'll just hang the cog on the wall for display but i may make a series of them and connect them to the propeller if i did make more i'd make them in an easier way using plywood and that would make them more achievable to make a bunch of them if that's something you'd like to see let me know i also thought about making it into a light fitting that could hang over our dining table and by the way i'm hoping to make a new dining table soon so look out for that some of you said it would make a great coffee table and i'm sure it could be used in many ways i put it up in our granny flat just to see how it would look but i think it will live in the workshop let me know what you would have done with it and while i'm in the granny flat i thought i'd show you this light fitting that i made years ago from caulking nozzles anyway for now it'll just be on display in the workshop and i do need to put an end cap over that bracket so it can't fall off hopefully you enjoyed the video if you did please like and subscribe thanks for watching and i'll see you on the next one
