How to Make a Large Plywood 'Cast Iron' Cog

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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Also you can check out my photography at my website (nothing to do with making but you may be interested in what I do) www.neilpaskinphotography.com
My email can be found in the about section of this channel.
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Pask Makes
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Australia

[@molegrip3860]

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 ! :)

[@brown56765]

I have a 3d printer and no bandsaw, but inspirational nonetheless XD

[@TehGureedo]

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.

[@MusikCassette]

well the hole workshop setup is more expansive than those tools would be. And sharing desings is easier with that kind of stuff.

[@Crewsy]

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.

[@PaskMakes]

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. 😊

[@Giddykippa65]

@@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

[@dale1956ties]

@@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.

[@emm_arr]

@@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.

[@dal2888859]

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 KZbin. Really enjoy your stuff.

[@PaskMakes]

Thanks very much Dallas! I think that was the most fun part of the project, figuring out how to actually make it. 😊

[@carenclemmons5002]

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.

[@dhammer5645]

Where's Mattias Wandel. He would appreciate all the woodgears.

[@nicktrousers]

Pretty sure hes subbed to the channel

[@UFTyop]

Helping behind the scenes. Looks like his big print program.

[@dhammer5645]

@@UFTyop that was my guess as well

[@PaskMakes]

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. 😊

[@UFTyop]

@@PaskMakes Great mindst think alike, evidently.

[@DustyFixes]

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.

[@roelhessels6007]

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!!

[@LyndonBontrager]

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!

[@ThePapa1947]

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

[@ronbunker5778]

I think the patina you put on this gear really shows the viewer that it is an old metal gear. Really well done!

[@bartylobethal8089]

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.

[@PaskMakes]

That’s a great idea Barty - I did look at the recesses thinking it needed some grime in there. 😊

[@glen1arthur]

If I didn't watch you make it - I would think it was real cast iron gear. Truly - A Work of Art.

[@johnshoureas1629]

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. 😀

[@jebowlin3879]

I think it looks pretty good, but your suggestion could go to improve it, js

[@Crewsy]

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.

[@sdoitla1431]

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.

[@halo-halo1204]

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 KZbin for recommending.

[@-Benedict]

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.

[@mattadulting]

And now you need to watch his other videos. You'll be a new subscriber I'm sure.

[@riccroft710]

That is a great example of perseverance. Really enjoyed your use of the templating bit in your router table.

[@alexold8183]

What a fantastic job, love the final painting process with the aged metal look

[@travisspore7257]

Honestly the rust with the sealer on it looks great in my opinion. Amazing work!

[@kenshores9900]

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.

[@jackknows6509]

I like how you did the treatment, looks like semi-rusted, semi-aged. A great job!!!

[@williamellis8993]

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

[@cepaasch]

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.

[@schlenbea]

This was mesmerizing! Absolutely fantastic build! Thank you for sharing your process!

[@nenaelliott8058]

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.

[@danjrash]

Great piece of art, love how it's coming together. Looking forward to the next cog videos!

[@juneritchie2498]

Enjoyed seeing it all come together! Also, congratulations on your new website and thanks for the plans.

[@PaskMakes]

Thanks June! 😊

[@mcgriffith2727]

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

[@davidmontgomery1016]

That is way COOL! I am looking forward to seeing the rest of it.

[@BrittCHelmsSr]

Simply Awesome. Love the distressing techniques.

[@DadzorRules]

Very cool! Can't wait to see the final product.

[@Lorddanielrushton371]

I'm really enjoying this series. The cogs are beautifully done. Thank you for sharing.

[@sudo_nym]

Looking forward to seeing this completed!!!

[@Bonzomallard]

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 😁

[@Zack-xz1ph]

love the look of the curved spokes on old cast iron gears/wheels. I've 3D printed some gears like that

[@luisconstruye3240]

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!

[@montanamoments9989]

Thank you for the free plans! I'll be buying more of your plans soon!

[@kzookid2051]

The different cog styles look great together.

[@Zogg1281]

That new cog looks awesome!! Can't wait to see the rest 👍👍

[@georgecunningham9175]

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!

[@PaskMakes]

I’m glad you enjoyed it George! 😊

[@mcswordfish]

These look brilliant. That rust finish is incredible. Love your work

[@cranegantry868]

Loved this. Lots of great skills went into making the cog.

[@EarlB252]

I think it turned out perfectly awesome. Great job. Thanks for the video.

[@kevinetheridge6153]

The distressing is cool. I like the more subtle rust you ended up with after the finish. Excellent as always. Cheers!

[@markchiswell2537]

I'm 45 seconds in and already I'm loving it. Great stuff, thanks for showing us what can and might be achieved.

[@kylebracht]

Great work, Neal! I loved that grime technique with the water and spray paint. Definitely will be putting that in my back pocket!

[@PaskMakes]

Thanks - glad you liked that, it worked very well. 😊

[@Maker238DeLoach]

Absolutely stunning job sir! I cannot wait to see them all put together and see them all turning together! Make On Brother

[@johnvaluk1401]

Wow coming along great. The rust effects really make it !👍

[@JamieBainbridge]

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.

[@ryanneumann5165]

I could watch your stuff all day - EXCELLENT!!!

[@Curly_Maple]

Utterly enjoyable! And the result looks great.

[@BrenainnJordan]

Lovely stuff! I think the rust effect and weathering techniques worked great!

[@tomim7187]

Wow! That's really cool! What a great feature for the workshop.

[@IanSmithKSP]

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

[@PaskMakes]

Thanks very much- it really does feel like it’s coming together! 😊

[@samanthadean1083]

I can hardly wait to see all the gears connected to the propeller!!! It’s going to be awesome!!! 👍🏻👍🏻👍🏻❤️❤️❤️

[@thegentlemanmaker]

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.

[@joeroscillo4015]

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!!

[@nickcosta3004]

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.

[@jquest90]

That’s awesome work! I like how the finish turned out. Looking forward to the rest! Keep up the awesome work!!

[@loucinci3922]

Fun project. Interesting finish. Looks good. Thanks for sharing

[@michaelm077]

Very cool, the display looks fantastic.

[@waterboy8999]

Looks bloody brilliant! Great work. I'm not the least bit jealous of your workshop.

[@ianvicedomini2648]

It looks fantastic Neil. hard to believe what it’s made of and the effect of the aging looks awesome. Great video mate 👍🏼👍🏼

[@absurdides]

Fantastic work sir, I really like the aging you did to the new cog, it looks spot on to me.

[@jackdernorsek5310]

THANK YOU. Thoroughly enjoyable and I wouldn't change a thing!

[@murphymmc]

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.

[@thomasbougher9902]

This is fantastic! Can’t wait to see the rest of them.

[@bradleytuckwell4854]

It’s looking awesome. Great content as always and I’m confident it will turn the propeller once it’s finished.

[@mexlemax3307]

Really super cool gears. It's hard to believe that this is made of wood. Very good work.

[@momsspaghetti6507]

that looks awesome mate!!! cant wait to see the final product!!!

[@blizatrex]

It looks great. I like your metallic finishes.

[@marksmith7147]

Brilliant decretive idea. I think it will look even more amazing as you add to it 👍🏻

[@OhHeyTrevorFlowers]

That is a seriously cool project with neat work. Thanks for sharing.

[@jmert_5859]

They look amazing.

[@TheducksOrg]

Expertly done - great work!

[@faisletoismeme]

I liked the way you use router template bits. You are a very clever man and very inspiring. thanks.

[@dnngskn62]

Well done and I think this one looks great. Looking forward to the others coming.⚙

[@martinlouden9005]

A great result Neil. That cast iron effect is very convincing!

[@jrmintz1]

I think the finish looks great! The proportions look right, it's very believable. Extremely cool project!

[@nickr8337]

These gears look amazing, better each time so far

[@paulrobertson5550]

This project is looking fantastic. What a great piece of wall art.

[@itsjustmetomc4848]

This was wheelie brilliant! As far as color choices, I think the ones you picked work well. Great video! Shalom

[@leon_mnl]

this is a cool series to watch , slowly coming together in to a functional piece of art , i love it

[@rickmoore]

That turned out great, can't wait to see the next few designs

[@Dadmadeit]

Great work, Neal! 👍 Beautifully done.

[@cirquemechanicsvids]

great video!!! thanks for sharing. I'm inspired to get back into the shop and give it a go. Like the wax /paint rub off scenic tip. Good stuff all the way through.

[@The_ADD_Maker]

i have been watching your channel for a while taking notes and then building somthing simuler. This one took me two months to make

[@patrickdecanio5599]

Absolutely amazing Job!

[@lukafilm]

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🤘

[@jimx1169]

Very satisfying to watch. Nice work as always!

[@picklerick8760]

Really nice work that came out beautiful

[@jimengr]

Very nice! Love the finish looks cool.

[@patricktdonovan]

Love these gears. So so cool and creative.

[@nobuckle40]

Real cool Pask! That rust colored finish is awesome!

[@lint2023]

That looks fantastic! Such a fun project!

[@FearsomeWarrior]

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.

[@davebashford3753]

Can't wait to see the whole wall when it's done!

[@Downtheshed]

Looks awesome. It’s like a casting pattern. Pretty cool, and the rust effect is good. 👍👍

[@jerryodell1168]

One Word- " Amazing "

[@26tp]

Fantastic work Neil.

[@trevorspice2122]

Thanks Neil for another great video. You certainly have some great ideas, keep up the good work ⭐⭐⭐⭐⭐ stay safe 👍