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Sometimes I have this intuition about a
specific idea that I just know going to
be awesome. Like really
awesome. And today I have an idea just
like that. We are going to make the
world's largest plywood gears.
Okay, so world's largest plywood gears.
I mean, why and how and how can you
help? Let's begin with why exhibit A,
the original marble machine. On this
machine, there was a lot of things that
failed, but the gears weren't one of
them. The gears that we see here
performed perfectly. 264 million views.
That's pretty good. There's something
with plywood gears. Okay, exhibit B, the
Mar Machine X. Also plywood gears. Of
all the problems I had with Marine X, no
problems with the plywood gears. And
look at them. They're just magnificent
and beautiful.
Right. Exhibit C. Matias Vandal's how to
make gears video. For me, this is where
like my journey with this began. So, I
do want to make a Renaissance marble
machine. This machine fits perfectly to
be created in wood. To make these gears
in wood would just sell the whole
Leonardo da Vinci Renaissance thing. On
my previous machines, I did normal
spurgearss just like Wilson with
straight tooth. And while those are
great, I have a new favorite gear which
is a double helical gear. So what I want
to do is to make double helical gear in
plywood. So you can see that the teeth
here are angled. I am not aware of
anyone who have done double helical
gears in plywood. It seems likely that
no well doumented examples of double
helical gears made from plywood exist
online. We would be the first. My lust
of creating these is enormous. These
gears gets me up in the morning. I get
so happy from them. Wouldn't it be much
better to use timing belts and pulley or
these beautiful metal helico gears? If
we would make gears this big in metal,
it would be so heavy. And then also
timing belts. Timing belts are great.
It's not fun to look at. It's just not
cool to look at. And I'm just not saying
that. I have an example for you. This is
a video from an engineering company DMG
Mory who have built a marble machine
with five axis CNC machining. So they
have the cool flip-flop uh marble
divider there. And I think this machine
showcases my whole point. I think this
company actually emailed me for
permission. I just say go ahead. I mean,
this is cool. All the parts. Super cool.
1 2 3 14 people unpacking the parts. I
mean, I'm super impressed by what
they've done that they like made this
project. And here comes the cool gears
and stuff. Wait, there's two screens of
sponsors. We have a bevel gear. We have
a chain. We never There's no sound in
this video. So, cool gears, but they're
filmed too close so we don't see them.
Marbles. Nice. Some kind of marble lift.
Oh, it's a wave marble lift. That's
cool. Oh, magnets. They used
magnets, which is kind of fun. And
programming pins. Beautiful. Beautifully
machined. Here's some marbles hitting.
Wow. What a machine. Let's see how many
views it has.
9,000.
9,000. Should we check how many views
the plywood gears have? I'm just going
to check here. Marble machine. Let's
check this video. 264 million. I
actually love this project. this machine
from DMG Mori. Well done. Kudos to you.
And there's an Apple and Sarah situation
here because they didn't try to do what
I'm trying to do. They tried to showcase
their five axis uh CNC machining
capabilities, which they did. And I'm
trying to do something else. I'm trying
to feel alive
inside. You know, when Bruce Springsteen
shouts, "Is there anyone alive out
there?" "Is there anybody alive out
there?" Yeah, because we're going to
make double helico plywood gears. Okay.
When I have this like enthusiasm that
has never gone wrong. I mean, no, the
first machine didn't work. That went
wrong in a way. The second machine
didn't work either. But reminder, it
wasn't the gears fault, actually. So,
this machine is my last exhibit about
why I want to make gigantic plywood
gears. So, that's why. And now I want to
tell you how I'm planning to make these
new gears. Step one, cutting the
profiles. We start with a CNC machine.
Then we start to manufacture all these
profiles. So there we go. These are the
profiles. Step two, making the assembly
jig. We're going to make a straightening
gluing up jig. This time we have some
MDF. We have another MDF. And then we do
some machining operation. We do these
cut downs. We're going to use these
T-nuts. We're going to put these T-nuts
in all these holes. Flip the MDF with
our X-ray vision. You can see the T-nuts
underneath there. So, next step, we're
cutting these alignment holes. And then
something important. We see these flats.
All the blue areas here now is CNC.
Perfect. Step three, glue
up. Now we can start assembling our
gear. We start with the wooden pegs and
now we can start with the first layer.
So here's the first layer in the middle
and then I start with the segments just
putting them on piece by piece around
the entire circle. We have our first
layer. We add glue and we put the second
layer on. And then we start with the
spokes. This whole layer is with spokes.
Another layer of spokes. Yet another
layer of spokes. This is 18 mm plywood.
Baltic birch BB highgrade quality
plywood. This is not your typical
construction plywood. This is like the
best plywood. There is another layer
here. And the final layer. At this step,
the precision is not important. The
flatness is a bit important. So that's
why I'm going to clamp this with M10
bolts. So we're lowering these M10 bolts
down. And they are meeting the T-nuts
underneath. But what's cool with these
M10 bolts is that we can actually clamp
with a torque wrench. So we can apply
the exact same amount of pressure evenly
across the whole glue up. The glue up is
ready and we just leave this to dry like
overnight or something. Step four,
machining the center bore. We just made
a plywood structure with no precision so
far. But here's where the precision
comes in. So we go in the middle and
we're going to machine a new center hole
with a CNC machine. We made this hole
underside. So we turn a small hole to a
precise larger center bar. We're going
to machine in a flat here. So then we
know that this flat area is precise
together with the center bar. The blue
surfaces does not need the glue up to be
precise. We add the precision after the
glue up. Okay. But how do we add a metal
shaft precisely to the plywood? Well,
we're using a metal hub. So we add a
metal hub to the plywood and then we
clamp it on with some bolts. And then
we're using a standard of offthe-shelf
part from SKF, the tapered bushing. When
we turn the gear around, we can see that
we have yet another tapered bushing on
the other side. So now the shaft is in
its place. Now we have the first point
of precision in the shaft in the middle
of this plywood blank, but the outside
has no precision whatsoever, and it
doesn't need yet. Step five, machining
the gear teeth. We're going to take the
plywood blank to a rotary CNC machine.
In the rotary machine, we're going to
use the fact that the shaft is precise
to put the gear in a rotary axis. And
then what we can do is that then we can
machine the gear teeth. So here we're
cutting the gear teeth and voila, we
have cut the gear teeth. This thing is
spinning around and the CNC spindle is
cutting from above or from the side
somehow, which means that the gear will
be very precise. Not at all what I
managed before. And remember when I CNC
2D, these gears worked. This will have
much better precision. So yeah, that's
how I plan to make these gears. And the
axle and the teeth will have this
precise relationship that is independent
of the gluing up. We can make small ones
and it's just going to be so
cool. I noticed that the double helical
gears I built for my 3D printer when I
had very low precision putting the gear
train together on my prototypes, they
kind of just worked super smooth thanks
to one thing, backlash. I'm not talking
about the backlash that I'm going to get
from this video. No, no, no. I'm talking
about the backlash measurement of a
gear. What is backlash? Let's pretend my
fingers are gears like this. If I put
them really tight, we have zero
backlash. But if I open my fingers, we
have some space between the gears. That
is backlash. And we can use it to our
advantage. In my helical gear generator
that I'm using, there's a backlash
option here. Backlash. A positive value
here causes each tooth to be slightly
narrower than the ideal tooth. In the
real world, having a perfect tooth is
not often desired. It is better to build
in a little backlash to reduce friction,
allow room for lubricant between teeth,
and to prevent jamming, especially if
you make gears from a material that can
shrink and expand. Right? We'll get to
that later. So, let's illustrate this. I
have two small helical gears here. So,
largest teeth, smaller, smaller again, a
little bit bigger, a little bit bigger.
So, here you can see the three different
versions I made of this gear with
different backlash. And if we put two
gears together, this is the largest
version. You can see that it's quite
tight here for for the gear tooth. But
what happens if we introduce some
backlash? Look at all that space. If we
go to the smallest, you can see that we
have a lot of room. If I would make the
gears from let's say aluminium or from
delrin which are super dimensionally
stable, we could have a smaller
backlash. But a small backlash also puts
high demand that the axles are perfectly
parallel and that the distance between
the center hubs is perfect. Perfect.
What happens when we introduce a little
bit of space between the gears is that
all those constraints, all those
requirements gets lightened up. It's
basically much easier to get the gears
to mesh in a nice way. Would I recommend
this for a gearbox in a car? No. The
RPMs, the revolutions are much faster.
The forces are much stronger. But this
is a light force, low RPM application
where the backlash can be allowed to be
huge, which eats up in precision.
Well, let's also talk about humidity and
the dimensional stability of BB-grade
highquality birch plywood. Wood will
expand when the moisture in the wood
goes up and shrink when the moisture
goes down. The strength of plywood is
that the layers are glued in opposite
direction. Every layer you have the
fibers going the opposite way. This
makes plywood much more dimensionally
stable than normal wood. Dimensional
change is generally less than 1% which
is still quite a lot of movement for
something as precise as a gear. What can
we do about this? Well, we can try to
control the humidity that the marine is
in. This is a common thing for all music
instruments like guitars and uh violins
and stuff. But for example, when we play
an outdoor festival in front of 70,000
people and it's raining and they still
turn up because we're they know the show
is great, we won't be able to control
the humidity. So I think we have to
design the marine to allow for the
humidity to change and then we can
actually treat the plywood lacquer and
varnish, wood oils, epoxy sealant. So in
conclusion, we always need to account
for the humidity, but we can improve it
by sealing the plywood and using great
plywood and allowing for the design with
some backlash to allow for some
movement. I think all those actions
together makes plywood a feasible
material to make huge gears from. So we
talked about why plywood gears and how
I'll make them. And now I want to talk
about how you can help me in this
project. I want to make the prototype as
soon as humanly possible. I don't have a
workshop yet here in Stockholm that can
do that. So in the link in the
description, I'm looking for metal hub
design feedback, metal hub machining.
I'm also looking if someone has a
flatbed CNC machine set up close to
Stockholm. Then I'm looking for a rotary
CNC machining. And then I'm looking for
partnering with a flatbed CNC machine
company for the entire Marine 3 project.
And I'm also looking for a partnership
with a rotary CNC machine company. And
I'm super happy for all your help. And
even more, I'm happy for 92 total
vintagaman backers. And you are all
helping me making Marvin Machine 3.
Thank you. And a huge thanks to the new
backers, Adrien, Alex, Alexander, Asco,
Chris, Dan, Daniel, Dennis, Eduardo,
Eric, Freak, John, Jordan, Kelly,
Carrie, Kristoff, Leandro, Malta,
Marcus, MC, Mary, Marime, Neils, Phil,
Peter, Prof, Holy, Radioactive, Magic,
Rafael, Raa, Roman, Steve, Squishy,
Brain, Gowen, Tahun, and Tim. Thank you
for choosing to support Mintan. That
means so much. And thanks to all
previous backers as well. So 9002. Can
we get to 1,000? That would be so much
fun. If we reach thousand backers, I'll
make the gears out of metal. No, I
won't. Never. Wilson always had a bad
attitude. He's been so obnoxious since
he learned that I'm returning to plywood
gears. I
believe not again. Wilson, come on. Can
you see that Delin Wilson is just paying
attention and standing nicely? I'll see
you in the Google forms. Right, I'm
going to withdraw to my
chambers and uh I'm thanking you so much
for watching and especially for all your
answers in the Google forms. See you in
the next one. Ciao.
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