How to Make a Large Plywood 'Cast Iron' Cog
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- เผยแพร่เมื่อ 6 พ.ย. 2021
- Get My Free Workbench Plans: paskmakes.com/limited-time-fr...
I often say how much I enjoy a project but this one really was a fun one. It was much easier to make than the original wooden cog that I made a while back as there wasn't any joinery involved. I'll make a few more and connect them up to my propeller. Fingers crossed, it may actually get the prop turning although I'm not super confident about that. Either way I'm enjoying making them and it should look great as a display even if they don't actually work.
As always I'm happy to answer any questions.
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Great video - no CNC, no laser cutter, no 3D printing, just regular tools just like 99% of the viewers would have. Inspirational. Thanks for sharing ! :)
I have a 3d printer and no bandsaw, but inspirational nonetheless XD
Sure, 99% of viewers have a bandsaw, a router table, a handheld router, a lathe, drill press and an assortment of cordless power tools. Oh and a huge workshop, bigger than my apartment. I feel ya.
well the hole workshop setup is more expansive than those tools would be.
And sharing desings is easier with that kind of stuff.
I think the finished gear looks great and the “rust” effect actually looks better once you added the clear coat.
The same thing would happen to dry powdery rust if you sprayed it with oil.
For more faux finish effects you could dry brush silver paint onto the contact surfaces of the gear teeth.
Thanks! I know what you mean, it does have that look. It’s just the dry rust looked more realistic although the sealed rust effect still looks ok. 😊
@@PaskMakes when i first saw the notification for this vid i actually thought you had cast it in metal from a pattern that's how good the finished cog looks well done
@@PaskMakes My wife sprayed clear lacquer on an old ashtray stand and added a pot on top to make it a plant stand and it looks great. Neither of us had ever heard of spraying lacquer over rusted steel/iron but she figured she try it and it came out great. I really feel that it's a viable option when faced with dealing with a rusted metal object. It sure cut a lot of steps and made finishing that plant stand a simple matter of waiting for the lacquer to dry.
@@PaskMakes I was going to say the same as the OP. I think your bright Aussie climate might make rust look brighter than it typically looks in the UK. It tends to be brown and drab here and the clear coat makes it look more like that.
I think the patina you put on this gear really shows the viewer that it is an old metal gear. Really well done!
I gotta say, every video I watch from you absolutely astounds me as to the dedication you possess to make what you want to make. I understand as a a craftsman that when one gets a vision (or when a vision gets a hold on us) and we see the way to make it a reality, it no longer matters how difficult it may be; we will follow through to completion. But you, sir, embody this force more than anyone on TH-cam. Really enjoy your stuff.
Thanks very much Dallas! I think that was the most fun part of the project, figuring out how to actually make it. 😊
It’s my opinion that your creativity is comfortably linked up inside your brain, lit up by the eyes of a photographer and constructed by the engineering carpenter that you’ve become. You are indeed a good, hot mess of talent. Keep the train a goin mate. And thanks for the ride.
If I didn't watch you make it - I would think it was real cast iron gear. Truly - A Work of Art.
When this came up in my feed, I didn't think I would find it all that interesting. I clicked anyway, and 20 minutes of absolute fascination later, here I am wanting the rest.
And now you need to watch his other videos. You'll be a new subscriber I'm sure.
Where's Mattias Wandel. He would appreciate all the woodgears.
Pretty sure hes subbed to the channel
Helping behind the scenes. Looks like his big print program.
@@UFTyop that was my guess as well
Tyop It looks like a great pice of software but I work on a Mac so it doesn’t work for me. I made the templates manually. 😊
@@PaskMakes Great mindst think alike, evidently.
Well I popped my head in the door to see what was happening and stayed having found myself transfixed. Excellent job, thanks for sharing and thank you TH-cam for recommending.
Honestly the rust with the sealer on it looks great in my opinion. Amazing work!
Very nice. As a retired wood pattern maker I have to say what you did this looks very real.
I have 2 very old pattern gears that the foundry was going to burn over 40 years ago so I took 2 of them. One is very large.
Great work I really enjoyed watching the video.
Gary
That looks Awesome! On the cog teeth. Even though the outer surface and deep between the teeth could be rusty, the mating surfaces would still be free of rust and maybe even a bit shiny. Love your videos.
A salute to you from the Netherlands. This gear looks fantastic, even better then the first one. We always view your video's with open mouth. From scrapwood challenge to propeller and cogs, bravo!!
This is so neat. Especially how the spokes look realistic. At a distance you could not tell it was a wooden gear. This is what would have been done to cast a gear. Again thanks. Enjoy the somewhat unusual projects you make.
Beautifully done, sir! I love the progression of your projects and how they all incorporate into each other. Can't wait for your next one!
That is a great example of perseverance. Really enjoyed your use of the templating bit in your router table.
Helpful tip: Try clear matt artist spray finish over your rust finish. It should dry with the effect that you want for the rust finish. 😀
I think it looks pretty good, but your suggestion could go to improve it, js
I have a feeling any clear sprayed over the “rust” will do the same thing since that’s how chalky finishes react to any clear coat whether it’s a matte or glossy finish.
Ask anyone that’s built and weathered scale models.
I like how you did the treatment, looks like semi-rusted, semi-aged. A great job!!!
That painted cog looks great!!! It was very surreal watching you pick the finished product up, looks like it should take 10 people or an overhead lift to pick it up.
One of the few channels I’m not clicking the right side of my screen repeatedly to FFWD through the video.
To further enhance the effect of 'weathering' on your new cog, give the whole thing a 'wash' (very dilute mix) of acrylic paints (black and burnt umber). Then before the paint has dried wipe away the excess with a rag. This will leave most of what paint remains built up in corners and recesses. Best to do in sections. Refer to Punished Props or Evil Ted for more details on weathering effects. Note that this is not to simulate the effects of being in the weather per se, but the effects of general usage.
That’s a great idea Barty - I did look at the recesses thinking it needed some grime in there. 😊
Your shop is looking really nice these days. Big contrast to when the channel started. This video really highlights why I love flush trim bits so much. They’re a miracle of modern engineering
Thanks very much- it really does feel like it’s coming together! 😊
Just having that much moving on the wall is a sight. The total mass on the wall being spun by one wheel will be incredible.
The different cog styles look great together.
I'm getting a little suspicious, I have a feeling that by the time all these propellers, cogs and what-not are built, Neil and family are going to fly away in their house which has now become a steampunk airship.
That great weathering. It looks like an old car from the 50s, made from good metal which lasts and where guys clear over the original scuffed paint to keep the patina.
i have been watching your channel for a while taking notes and then building somthing simuler. This one took me two months to make
One Word- " Amazing "
I like that you also show some of the mistakes and the "how to's" for fixing them. This does highlite the creative and planing process quite well.
this is one of those projects that could be done alot easier with a CNC but wouldnt be as fun. Pask is the king of tedious projects anyway! :D
A CNC is not the go-to tool of a real carpenter, it is the go-to tool of a LAZY carpenter. We now know which you are.
@@vargr Wow you really showed that guy!
I did think about whether to get a CNC just for this project. I was thinking I’d make the first one as I did and make the rest with a CNC but that didn’t happen. 😊
I think your finish on this new "cast iron" cog is absolutely brilliant.
after you round the spokes, it looks really pretty. You could make a tree of life with it and it'd loook amazing
Brilliant! For the life of me I can't decide who had more fun with this project - You making it, or me (us) watching you make it............future segments of this project are highly anticipated, I assure you!
I’m glad you enjoyed it George! 😊
Having watched loads of home casting videos, I initially thought this wooden piece was a cast for a mould, but then realised that it was more than that, especially when you started to coat the finished item to make it appear as the, 'real thing.' Ideal for businesses that are looking for reproductions of such items primarily for display purposes.
🐼 Big Bear Hugs from a 68 yr old grandma in Kirby, Texas, USA 🐼 ❤️ 🎀 ❤️ 🎀 ❤️
I love that finish trick with the water and spray paint. That looked super realistic, probably because that's how spatter and grime would build up in real life.
love the look of the curved spokes on old cast iron gears/wheels. I've 3D printed some gears like that
If I hadn't watched you make that cog, I would have said it was cast iron. Thanks for sharing this with us. :)
I'm a big fan of your scrapwood challenges, but I really enjoyed this video too
I could watch your stuff all day - EXCELLENT!!!
These gears look amazing, better each time so far
I really enjoyed that Neil. Turned out very nice. I enjoy your attention to detail and your way of going about woodworking sequences. Switching to the half inch was exactly what I was thinking and your did it!!
I wish you were my uncle. From sunny Weymouth UK 😁
What a fantastic job, love the final painting process with the aged metal look
I can hardly wait to see all the gears connected to the propeller!!! It’s going to be awesome!!!
👍🏻👍🏻👍🏻❤️❤️❤️
The rust effect turned out amazing.
Awesome, I can't wait to see the propeller spinning
I'm always confused by the down votes.
Thanks for the free plans. I have a bench already but I reckon it's not a sturdy as yours. I've never followed woodworking plans and this seemed like a good project to start with.
Outstanding work, done the hard way!! Beautiful piece, through miles of patience and miter work !! I imagine, you could make a giant Rolex watch, to scale!!
Really super cool gears.
It's hard to believe that this is made of wood.
Very good work.
I'm so excited you're going to power the propeller!!!!! What a fantastic and inspiring project, brb, gonna make one from cardboard now.
I love your work, and how you work. It simply shows how much more i have to learn.... but with the results of that labour! love it
Great work, Neal! I loved that grime technique with the water and spray paint. Definitely will be putting that in my back pocket!
Thanks - glad you liked that, it worked very well. 😊
I often use a cool weathering technique in my miniature builds. Use a dishwashing sponge (the rough side), dip it in rust colored paint, and dab it on all the edges where you want to mimic chip-out. Works great. Btw, loved this video! Your channel is probably my favourite makers channel! Keep rockin🤘
I definitely like watching your videos even if I don’t have all the tools you use I can get ideas from them
Fantastic job. Did a rust finish on a large steel frame used as a structural support in a doorway years ago. Sprayed an acid concrete stain on it to get a rust finish, it worked very well. Then sealed it with a clear urethane, it did change the effect more than I wanted. John Shoureas tip posted will come in handy. If you want an aged, weathered wood look, soak some steel wool in vinegar to make a rust solution (2-4 days, remove it periodically to let the oxygen accelerate the process ) . It will react with the tannin in the wood and "weather" it. Every species reacts differently, some take 20-30 minutes, others, like oak give immediate results. The faster the reaction the darker the end result. Fun to experiment. A weathered wood cog may be a cool addition.
if your projects didn't end up so brilliant, I'd say you were probably insane to attempt them. But, instead I guess you are a genius after all. You inspire me even though I would never attempt something like this. I constantly say...."Give it a go" now. That's my motto and where I've personally grown by watching your videos.
Mr. Pask, you never cease to amaze me, I love how the gear turned out, the amount of work on the teeth and the paint job is perfect, I look forward to seeing how the complete project turns out, by the way, these longer videos, keep it up, not boring, it's just a pleasure to watch this!
I liked the way you use router template bits. You are a very clever man and very inspiring. thanks.
The whole display is looking good. I don't know what I would do differently if anything. I'm looking forward to seeing the rest of them.
Bill
I can't wait to see it totally complete. I'm loving it so far. So unique. I don't want to rush you though. I'm enjoying every episode.
Hi Neil, I worked on pretty big Hollywood movies for decades and we often had to make “metal finish” props often from wood to lessen the weight and to be less dangerous in a stunt or pyro explosion: getting a metal finish as good as you got would be a challenge for an extremely experienced scenic painter using every trick in the book! You did a seriously camera-ready ace job there pal. 👍
Thanks very much John! :)
Thanks for the FREE plan! I really like my "PASK MAKES" coffee mug.
The distressing is cool. I like the more subtle rust you ended up with after the finish. Excellent as always. Cheers!
Nice work! As someone who works with props and weathering, I really enjoy making fake metal and things that look heavy and old that in reality are lightweight wood or foam pieces!
I'm 45 seconds in and already I'm loving it. Great stuff, thanks for showing us what can and might be achieved.
That’s Awesome! The ol-router got a workout on this one! Cheers!
I'm really enjoying this series. The cogs are beautifully done. Thank you for sharing.
Great piece of art, love how it's coming together. Looking forward to the next cog videos!
Excellent. can't wait to see it all done up. I would like to see you put a small (very slow and weak) motor on it to see the whole thing move (again very slowly). A gentle and stead spinning of all the gears would be great.
I'm quite certain the patternmakers of several generations ago would be smiling if they saw you building up the wood pieces.
Absolutely stunning job sir! I cannot wait to see them all put together and see them all turning together! Make On Brother
Can't wait to see the whole wall when it's done!
This is becoming quite a serious piece of art work that I'm sure people will be lining up to admire and certainly offer to purchase! I think it looks awesome and it's not even done yet. Fantastic job sir 👏 👍
Thanks very much James!😊
These look brilliant. That rust finish is incredible.
Love your work
This was mesmerizing! Absolutely fantastic build! Thank you for sharing your process!
No complaints here. That looks amazing
That new cog looks awesome!! Can't wait to see the rest 👍👍
Oh yes! Fantastic stuff, I love your wooden cogs. I’m reminded of the workings in the 1814 windmill in Cranbrook, just a few miles away from me. It’s fascinating to visit and see just how these things work still.
That is way COOL! I am looking forward to seeing the rest of it.
this is so amazing, and I think the rust coat looks pretty great still, and the undercoat plus the top coat / grime, looks super cool.
Thank you for the free plans! I'll be buying more of your plans soon!
Simply Awesome. Love the distressing techniques.
That’s awesome work! I like how the finish turned out. Looking forward to the rest!
Keep up the awesome work!!
A great result Neil. That cast iron effect is very convincing!
It’s looking awesome. Great content as always and I’m confident it will turn the propeller once it’s finished.
It looks fantastic Neil. hard to believe what it’s made of and the effect of the aging looks awesome. Great video mate 👍🏼👍🏼
This is fantastic! Can’t wait to see the rest of them.
Loved this. Lots of great skills went into making the cog.
this is a cool series to watch , slowly coming together in to a functional piece of art , i love it
Wow! That's really cool! What a great feature for the workshop.
Real cool Pask! That rust colored finish is awesome!
You have the patience of Job, Neil. It feels like you have taken wood gear making to a whole new level with the love of making! So impressive a build and finish, and a great mesh despite the convoluted spur and rack style teeth!! Really looking forward to where you are going to take this based on your CAD model. Thanks always for your great content and tips and tricks to making whatever the mind can imagine! ~PJ
I think the finish looks great! The proportions look right, it's very believable. Extremely cool project!
FANTASTIC! I like the contrast of your designs. And I think the aged effect you applied looks the part: a used part on a piece of working equipment. I agree with you - I think the powdery rust looks a bit more realistic. Perhaps leaving the "oiled" look on the contacting parts and powdery on the sides?
I can't wait to see the next cogs! This is a great project and reminds me of the Hamilton watch display the jeweler had on his wall when I was a kid. All the cogs and springs spread out so you could see how a clock or watch worked.
I think it turned out perfectly awesome. Great job. Thanks for the video.
Very cool! Can't wait to see the final product.
This "gears" series is so cool! I Love the idea of using them to drive your propeller.
Brilliant decretive idea. I think it will look even more amazing as you add to it 👍🏻
Wow coming along great. The rust effects really make it !👍
This project is looking fantastic. What a great piece of wall art.
Well done and I think this one looks great. Looking forward to the others coming.⚙