Smith's PP1 "Pocket Pal" Multi-Function Sharpener

I haven't done a mini tool review in a while. Well, I've found something that truly deserves mention. I was lucky enough to receive the Smith's PP1 "Pocket Pal" Multi-Function Sharpener as a holiday gift. I have sharpened my share of knives, carving tools, and chisels. I've also purchased a lot of tools to do that sharpening. So, I admit, I was a little skeptical about this pocket-sized sharpening tool. My trusty Swiss Army Knife doesn't get the same attention that my woodworking tools get, so I decided to try the Smith tool on it. I ran the dull blade through the carbide slot a few times, then the ceramic slot a few times. The difference was incredible! I have yet to use the tapered diamond part of the tool, but I don't sharpen too many serrated blades. It can, of course, be used on non-serrated blades too, as well as on small gouges, scorps, and even fishing hooks. This tool is well worth the price in my book.

Here is a link to Smith's PP1 Pocket Pal Sharpener on Amazon.

[ Thanks Kev! ]

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A 'Convolution' of purely wooden mechanisms

Woodworker Ken Schweim built this collection of wood mechanisms and titled it Convolution. It is a wonderful assortment of drives, linkages, and gears. Well done, Ken!

From the video description:

This is a collection of wood mechanisms driven by a common wood crank. The entire project is wood, no nails, screws, wires, etc. Each assembly is removable. The wood is primarily common pine with some black walnut. Total time required was about 4 months with the majority in the design phase. I was going to add more to the open sides and the interior but decided against it for two reasons; one - it would require more cranking power and two, it would make it difficult to see the existing interior mechanicals. Plus, it now leaves the door open for another possible project to explore more wood mechanisms. In reviewing the audio I mistakenly said there is wire in this thing but not so, it is all wood.

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Video of 'Making Mechanical Marvels In Wood'

If you've ever wondered if the book Making Mechanical Marvels In Wood contains projects that would appeal to you, check out the video above sent by Richard Thorne. Richard has made four of the book's 17 projects and demonstrates them briefly in the video. Well done!

If you are up for working on some challenging, but rewarding woodworking projects, here is a link to where you can pick up a copy of the book Making Mechanical Marvels In Wood.

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Making Wood Trucks & Construction Vehicles

Time to start making some gift for the holidays. Why not make some wooden trucks and vehicles? Beautiful, durable, and without those annoying sound chips.

Product Description:

An old favorite gets a fabulous freshening up, with full-color images throughout -- but the projects remain as wonderful as ever, appealing to children of all ages. Bulldozers, dump trucks, loaders, and forklifts, each with a variety of moving parts: all these toy vehicles are included for the making, with plenty of diagrams, very detailed instructions that proceed logically and clearly from part to part, and images of the final product. Try a box trailer with a semi-cab, doors, axles, wheels (with simulated tread, if you like), and mud flaps. They're fun to craft and fun to receive.

Here's the link for the book on Making Wood Trucks & Construction Vehicles

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Great Book of Wooden Toys: 50 Easy Projects

This looks like a good book on making wooden toys. Anyone out there have this one?

From the book description:

Detailed and copiously illustrated, this in-depth handbook offers instruction for constructing more than 50 wooden toys designed to appeal to a child’s sense of imagination and playfulness. A brief introduction covers the basic techniques—gluing, sanding, and making wheels—and each project presents a meticulous diagram, a handy materials list, step-by-step instructions, and a photograph of the completed toy. Designs include stylized versions of a Model T car, a crane, and the Spirit of St. Louis airplane, as well as projects specifically for beginning woodworkers, such as pull-along trains and circus animals. Instructions for finishing and detailing ensure that the completed crafts will last for years.

Here is the link for more information about Great Book of Wooden Toys: More Than 50 Easy-to-Build Projects

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Proxxon Scroll Saw for model and toy making

I already own a decent scroll saw so it would hard to justify this purchase. But...maybe it's not to late for you!

From the product description

This is the ideal machine for that delicate project: model building, toy manufacturing and precision work. It cuts soft wood (e.g. bass wood) up to 1 3/16" (30 mm), hard wood up to approx. 25/64" (10 mm), plastic (including circuit boards) up to approx. 5/32" (4 mm) and non-ferrous metals up to 5/64" (2 mm) with standard scroll saw blades. The machine has a very stable ribbed die-cast aluminum saw frame with 11 13/16" (300 mm) throat. The blade guide is equipped with an integrated blower. The patented head-part is height-adjustable in 3 positions and offers numerous advantages: The lifetime of the saw blade is tripled after shortening it twice (teeth in the middle part of the saw blade are finally used, too). With the head in the lowest position, working with a blade shortened to 2 23/64" is even more precise. The machined worktable of die-cast aluminum has a size of 6 19/64" x 6 19/64" (160 x 160 mm) and is equipped with an adjustable longitudinal stop and graduated miter gauge (0-90°). The ABS plastic body provides a very practical sliding door on the right side of the housing for the removal of saw dust. The saw is powered by a 110 - 120V motor (85 W) for prolonged use, low noise performance and even supported by a quiet and wear-resistant toothed belt drive, running in a ball bearing assembly. The machine offers an electronically controllable stroke rate from approx. 150 - 2,500 strokes/min.

Here's the link to the Proxxon 37088 DS 115/E Scroll Saw

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How to make a super accurate vernier protractor

Check out this cool DIY article by Steve Garrison on how to make a protractor accurate up to 0.1 degree.

How it Works (from Steve's site):

Since this protractor uses a bubble level it can only measure vertical angles. The bubble is zeroed up on a reference surface by rotating the disc that the vial is attached to until the bubble is aligned with a mark and the front wing-nut is locked down. Then the protractor is placed on a tilted surface and the larger disc is unlocked (using the wingnut on the back) and the disc is rotated until the bubble is again aligned in the same position, then the rear wingnut is locked back down. The angle is read to a degree where the long line on the left side of the vernier points to the degree scale - read the smaller number. The angle is then read to a tenth of a degree by seeing which of the vernier lines matches up best end-to-end with the degree markings and added to the degree measurement. The markings on the vernier are 0.9 degree apart.

Here is the link with details on how to make your own compact protractor accurate up to 0.1 degree.

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8" slow-speed grinder on sale to end of August

Woodcraft is offering this 8-inch slow speed grinder on sale from now until the end of August, 2009. Regularly priced at $110, it is now on sale for $95. The grinder comes equipped with 120 grit and 60 grit white aluminum oxide grinding wheels.

From the grinder description:

This quiet, smooth 1/2 HP, 1725 RPM slow-speed grinder is great for sharpening tools without generating the tool destroying heat that you get so quickly from 3450 RPM grinders.

Here's the link for more info 8 inch slow speed grinder.

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Great used book - How to Make Animated Toys

A very affordable volume (purchased used) this book features detailed plans and scaled drawings for 30 different animated wooden toys. The author also goes into some detail about the processes of designing and building good toys -- including writing about child-safe materials and finishes. Projects include a waddling duck, a hopping rabbit and a lumbering gorilla.

Here's Amazon's page where you can buy a used copy of How to Make Animated Toys

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Proxxon hand-held minature belt sander

Designed for sanding in spots where there is limited space, this little power belt sander works on flat surfaces, corners, and curves. The sanding head tilts to provide access to difficult spots. The belt speeds may be adjusted from 300 fpm to 700 fpm. The sander features a quick and easy belt change system and belts that come in 80, 120, and 180 grit.

Here the link for the Proxxon Hand Held Belt Sander

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23 Piece Hobby & Craft Tool Set for under $15

I'm a little smitten with this hobby knife and tool set offered by Woodcraft.com. It contains all the things you would expect from one of these sets such as assorted knife blades, handles (3 actually), and a saw blade. But it goes beyond the norm with a inclusion of a tiny spoke shave, block plane, balsa strip tool, sanding block, and tweezers. It comes in a plastic case designed to fit each item. For $15 USD, this looks like a nice starter set for model making or working with any type of wood miniatures (model railroad, planes, boats, carving, etc).

Here's a link to this 23 Piece Hobby and Craft Tool Set.

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Proxxon Micro Band Saw with optional wet cutting

From the Amazon.com Product Description

A solid, ribbed die-cast aluminum housing (not a tubular or sheet metal construction) ensures the necessary stability. The machine has double ball bearing aluminum pulleys, a sturdy machined table with a slot for the miter gauge as well as the coolant trough. The worktable tilts up to 45° for accurate miter cuts. The low noise 110-120V motor (high quality, for quiet, prolonged use) operates via toothed belt. Electronically controlled speeds for exceptionally accurate cutting (no subsequent finishing necessary) are available from 395 to 820 ft/min. A practical table at the outside of the machine housing indicates the recommended speed for various types of material. The blade size of 13/64" x 1/64" (5.0 x 0.4 mm) is ideal for fine work, allowing to cut even smallest radii. The machine is equipped with a vacuum-cleaner adapter to help you work in a dust-free environment.

Here's the link to the Proxxon Micro Band Saw

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Wooden camel toy driven by a cam mechanism

This is a cam-actuated camel toy designed by John Hutchison. The plans for the toy were part of an article in the Woodworker's Journal December, 2000. This particular one was built by a gentleman named Mike for his grandson. A cam is attached to the back wheel axle which drives a dowel that in turn causes the humps, head, tail and legs to move up and down when the toy is pushed.

Here is a page with the builder's notes and several pictures of the wooden camel cam-driven toy.

[ Thanks Charles! ]

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Building a real woodworker's workbench

Here is a great Instructable on how to build a high-quality woodworking bench based on a set of plans originally published in Fine Woodworking Magazine (the best magazine of its kind, in my opinion).

The design used here is simplification of a bench from Sam Allen's book Making Workbenches.

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Proxxon 38481 IB/E Professional Rotary Tool

While most of us are familiar with the versatile rotary tool, we tend to equate it with the Dremel brand name. I have owned many, many Dremel tools and do not have any serious complaints.

Still, this Proxxon profession model appears to offer some noticeable improvements. The manufacturer claims that this model can be use for extended periods when polishing, grinding, cleaning and engraving -- without becoming overheated. That is one problem I have had in the past, but I think I pushed the poor Dremel too far.

Like the better models of Dremel rotary tools, this Proxxon can be run at a range of speeds from 5,000 to 20,000 RPMs. Variable speed is a an important feature in any make of rotary tool.

Finally, the Proxxon features a die cast aluminum head which serves as a study housing for the steel spindle, running within a ball bearing assembly. This strikes me as more robust than most Dremel tools.

The unit comes with six collets (sized 1/32", 1/16", 5/64", 3/32", 7/64" and 1/8") and is compatible with a number of Proxxon accessories such as a foot switch, flexible shaft, and drill stand.

Here is a link to the Proxxon 38481 IB/E Professional Rotary Tool

Note: Those of you who know you will be using a rotary tool a lot, should consider something like the Foredom rotary tools that jewelers and serious woodcarvers use.

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Carving tools sets with interesting handle design

I've used the traditional carving knives, chip carving knives, and palm carving tools, but I can't say I've ever used a carving knife with this style of handle.

I gather that the handle design is meant to serve two purposes. They can be held fully in the palm for larger, forceful cuts, or griped by the narrow part at the neck -- rather like a pencil -- for finer cuts. It sure sounds like a good idea.

Woodcraft has a seven piece set (shown here, $50) and a a five piece set ($40). Both come in a storage box of some sort.

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Koch Studio Kollegs - carving instruction manuals

Koch Studio Kollegs are written by master carver Kurt Koch. Each Kolleg focuses specifically on building your carving skills in a particular area while also covering proper tool selection, handling, and use. They feature numerous illustrations and photographs along with easy-to-follow instructions in four languages: English, French, German and Spanish.

From the product descriptions:

Kolleg #5 - Hands
Instruction in carving the seven known carved motives of hands: The working hand; the hand of the crucified; open hand of a woman; hand with firm grip, half closed hand, hand grabbing something fine and hand of an infant. 44 pages. Over 340 photos.

Kolleg # 10 - Heads
Instruction in carving the different faces (heads) that lend itself to a family grouping: Young lady, child and man with beard. 40 pages. Over 340 photos.

Kolleg #30 - Climbing Clown
Instruction in carving a clown climbing a rope. Once finished you'll be able to actually hang the clown from a piece of rope. A large carving approximately 19" tall, this project is generally regarded as one for the more advanced carver. 52 pages. Over 350 photos.

Kolleg #46 - Standing Bear
Instruction in carving a standing bear approximately 15½" tall not including the base. Over 81 steps, 365 photos along with copious illustrations guide you through the project. Considered a project for the more advanced carver. 56 pages.

Here is the link to the Koch Studio Kollegs - carving instruction manuals.

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Micro carving tools for very small wood carvings

The other day I mentioned the Rick Bütz woodcarving knives I use. While about 70 percent of the time I use either the standard carving knife or the detail knife, there are times when a specially shaped carving tool is just what you need. For a long time, I struggled with a mediocre set of palm carving tools. Mine didn't hold an edge very well and were just too big to be very useful.

A few years ago I discovered these unassuming little micro carving tools. They may look simple but they are hand forged, tempered, and tested for a correct edge profile. Not only that: they come sharpened and ready to use. Hallelujah!

They offer sets like the one shown here in three different sizes -- 1.5mm, 2mm, and 3mm. I went with the 2mm and am very happy with it. The micro carving tool set I bought has single and double bevel chisels, a skew chisel, a 90 degree V-shaped tool, and U-shaped gouge. All in cherry wood handles.

Here's the full line of Dockyard micro carving tools.

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Rick Bütz two-knife woodcarving set on sale

If you are a wood-carver or interested in learning, I came upon this deal from Woodcraft Woodworking Supply. This is a set of Rick Bütz carving knives -- the same to I use to carve the figures of my wood automata.

Rick Bütz wrote the book on wood carving. No, really...he DID write the book called How to Carve Wood. He also wrote a great book on How to Sharpen Carving Tools. Both are excellent.

The two knives shown are a standard carving knife (bottom) for most roughing out and carving and a detail knife (top) for doing fine cuts. Together, they should be the only knives you'll ever need. Now...other carving tools...well, you may want/need those in time, but this is a great start. Don't mistake these knives for the ones you find at your local arts and crafts chain store: these are much better. I learned this the hard way.

Woodcraft offers either knife individually, or will give you a great deal on the two -- saving you 33% -- through March 31, 2009.

Here's the product page for the Rick Butz two-knife woodcarving set.

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Fantastic all-wood blinds with helical gear system

Check out these absolutely fantastic all-wooden blinds.

The blinds utilize a beautiful set of wooden helical gears made with a technique that Steve Garrison created. The blind slats and the frame are walnut, the handles are pecan, and the gears and pulleys are made of cherry. Very nice, indeed.

Visit Steve's web site for information at www.stevengarrison.com.

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Miniature woodshop models with amazing detail

Setting the scene for an automaton often requires making miniature versions of things. Having done bit of this myself, I can really appreciate the work of David Brookshaw who makes 1/12-scale miniatures of tools and workshop equipment.

Brookshaw is working on a fully-equipped Victorian workshop. In the photo above that is a U.S. Quarter clamped to the bench vise!

You can visit David Brookshaw's web site to see more photos of his work

[ Thanks Charles! ]

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Making amazing wooden gears

Here are some samples of gears made by Steve Garrison. He has developed a technique that enables you to make any of the gears of the type shown in this video by using either a scrollsaw or a tablesaw. You can make straight-tooth or helical gears.

From his description:

There are no paper patterns to glue to wood and saw around, the correct involute tooth profile is automatically generated. This technique is very simple once you see how it works. There is no need for expensive cnc routers or lasers or any computer-controlled tools. If you have a scrollsaw or tablesaw, the ability to cut accurately sized circles from plywood, and a computer - then you can do this. You won't find this technique anywhere else, I have looked thoroughly and know it is my own original idea.

Visit his web site at http://www.stevengarrison.com/ from that home page click on the "gears" link to purchase Steve's technique. The price is $30.

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Trebuchet and Catapult Gift Guide from MAKE

The holidays just got a bit more..um...Medieval. I am so happy to share with you MAKE Magazine's complete Gift guide for the trebuchet and catapult maker. Build one, learn things, and by all means -- fling something!

(I am staunchly pro-catapult. There, I said it.)

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Free plans to make wood barking dog automaton

A while back, Lee Valley Tools published the first of a two-part article on automata by our friend Charles Mak. In this second installment, the author provides full instructions and plans for making a wood automaton of a barking dog. Automaton plans are not easy to come by so this is a rare treat!

Here is the link to Charles Mak's article on how to make a barking dog automaton courtesy of Lee Valley Tools.

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Article on "Automata: A Fascinating Woodcraft"

Charles Mak is a woodworker, automata-maker, writer, and true friend of The Automata / Automaton Blog. The first of his two-part article on automata is now available online at the Lee Valley Tools web site.

In the article, the author describes contemporary automata, gives an overview of their history, and introduces the reader to the process of making wood automata. He concludes this first installment with some great suggestions for further reading and some useful online resources. Stay tuned for the second part of the article in an upcoming woodworking newsletter!

Here is the link to the article Automata: A Fascinating Woodcraft, by Charles Mak.

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Del's Beautiful Wooden Machine - Final Details

I posted a while back about Del Short's Amazing Wooden Contraption. He's added the final details and the machine is now finished.

The best news of all is that he says he has some new ideas and will probably work on them! Personally, I cannot wait to see what this master craftsman comes up with.

I also love the way Del and Art interact. I am putting my vote in for a cable TV show.

[ Thanks Del and Art! ]

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How to Make a Circle Cutting Jig for a Router

Perhaps you've been inspired to make a wooden machine with some rather large pin-wheel type gears. There are many ways to cut circles including freehand on a scroll saw or band saw. You can also make or buy a circle cutting jig for the bandsaw. Additionally, you can consider using a fly type circle cutter or using a hole saw in a drill press.

Here is a complete article on how to make your own adjustable circle-cutting jig for a hand held router.

Unlike many a circle-cutting jig for the router, this one overcomes a common limitation -- cutting a circle with a radius shorter than the distance between the router bit and the pivot on which is spins.

John English came up with the ingenious jig you see in the photo above. It doesn't rely on a pivot point, which means it can be used to cut range of circle sizes.

Here is the article on How to Make a Circle Cutting Jig for a Router

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Lathe Basics: History, Tools, and Safety Article

Here is a great three page article covering the history of wood lathes, the tools currently used, and safety considerations.

From the article:
"One of the greatest features of turning is the chance to gain enough knowledge in short order to make finished projects in just a few hours--lathes give us the possibility of completing, including finish, many worthwhile projects inside a single evening. "

The article is courtesy of Woodcraft, who sells a full assortment of lathes, lathe tools, and lathe accessories.

Here is a link to the article on Turning Basics: History, Tools, and Safety.

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Woodcraft Woodworking Store Sale Items

Woodcraft is one of my favorite woodworking supply stores. They always have some sale items -- often several hundred. They sell some really high quality stuff like the Lie-Nielson bench plane shown above. (Sadly, this item is NOT on sale.)

They also have articles and videos to accompany many of the products they sell.

Visit Woodcraft's Sale Section to see what they've got.

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Amazing Wooden Machine Video with No Metals

With the exception of Brad Litwin's piece entitled Extra-Universal Movement, I don't know if I've seen such an elaborate hand-cranked wooden machine. This gentleman has constructed an amazing device using only wood and glue -- no nails, no screws or ball bearings. It is quite an achievement. It is my sincere hope I'm doing things like this at 70 years old. Bravo!

[ Thanks Falk! ]

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Screw & Bold Removers, Screw Extractors & Plugs

I hate to admit it, but even I mess up sometimes. A lot, actually. I use mostly brass screws, and they can strip easily if I use a cordless drill to drive them. Here are two options for saving the day. I own both. I NEED both.

The first is the ProGrabit Screw and Bolt Remover. I use this piece when I have stripped the head of a phillips head screw. This 3 piece kit contains everything you need to remove screws (sizes 4 thru 14) and small bolts.

To use it you, place the appropriate sized extraction tool in you drill in and run it in reverse to create a cavity in the screw or bolt head. You then flip the extraction tool in your drill so that the screw end can be inserted into the cavity. Again, running the drill in reverse, you back-out the screw or bolt.

The second option is the Cut-around Screw Extractor. I use this when I have snapped the screw head off of the screw completely.

You simply chuck this miniature hole saw into your drill, center it over your broken screw, then cut a plug out of the wood with the embedded broken screw in it.

When finished, you have a nice clean hole where your mistake once was. You can then plug the hole with standard size dowels or plugs cut with a tapered plug cutter. Cutting your own plugs will allow you to match the wood type, color and grain closely if you have some scraps from which to cut the plugs.

Functioning Wooden Steam Locomotive Model

Harold Manwaring made this scale locomotive entirely from recycled wood (bravo!) with the exception of a few small metal parts. Everything on the model works, though it does not go anywhere because its driving wheels are suspended slightly above the model track.

The model runs on compressed air that is fed at about 15 PSI to a small stainless steel receiver in the engine's firebox. Lines to the two cylinders are wood, as are the cylinders, and pistons themselves. The pistons are even fitted with wooden piston rings!

The craftsman says of the model:
"I had to use as close tolerances as possible as compressed air does not expand like steam, but also taking into consideration humidity and how much the wood would move. Two air lines run from the cabin valves out to the whistle and one to the valves. The whistle blows at about 2-3 lbs of air and the engine runs really well at about 12-15 lbs of air and stops at 8-9 lbs. It worked on the first attempt, so I stopped and had a beer."

Here is a nice article on the Harold Manwaring and the wooden steam locomotive. Also be sure to check out this video clip showing the wooden locomotive in operation.

Build Hidden Compartments into Wooden Drawers

This post may seem a little off-topic, but I'm going to justify it because a) it's about woodworking, b) it's mechanical in nature, and c) it's just plain cool.

Who doesn't love trap doors and hidden compartments?

This is a short, but useful article describing a few different ways to build hidden compartments into chests, bureaus, jewelry boxes, or even cabinets built into a wall.

Here's the article on Building Hidden Drawers courtesy of Woodcraft.com.

Dug North Automaton Plans Bootlegged on eBay?

Well, I honestly don't know whether to be flattered or indignant. A good reader of The Automata / Automaton Blog alerted me to the fact that someone on eBay is trying to auction off plans for my Training for Christmas automaton. Above is a screen shot of the listing.

I suppose if someone is willing to sell bootleg plans of my work (at least that's what they seem to be), I've reached a whole new level of fame. Perhaps these are actual pages from the magazine, which may be legit to sell. It's kind of hard to tell.

The plans are from an article I wrote for Woodcraft Magazine's Holiday 2005 issue. The article describes how to make the piece step-by-step with some plan drawings and many color photographs.

If you would like these plans, I would recommend simply buying a back issue of Woodcraft, which includes my article and dozens of other holiday-themed projects.

I may consider republishing the project (with my own images) at a future date. (I need to review my own agreement.)

Here's a link to Woodcraft's site where you can order the Woodcraft Magazine's Holiday 2005 Issue.

Proxxon Micro Plunge Router for Miniature Work

I haven't tried a router this small (1/5 HP), but it sure does look like a good size for model and automaton making. This little router allows you to round-over, slot, counter bore, and remove stock from wood and other materials.

Some details on the router from Woodcraft:

* Depth adjustment of 0.008" increments
* Easy router bit changing with the shaft lock button
* Support columns are positioned so you can see as you cut
* Integrated suction device for connecting to a vacuum
* Parallel and circle jig made of die-cast aluminum
* Die-cast aluminum base and smooth gliding polycarbonate face
* Includes 6 pc. collet set
* Comes in plastic case

Here's more info on the Proxxon Micro Plunge Router

Video: So You Want to Make a Wood Gear Clock?

Here's a low-pressure introduction to making a clock from wooden parts -- gears and all. Along the way, you learn many important techniques that could be used for automata making as well as clock making. The narrator discusses tools, specific methods of work, and the construction process in general. The film gives you a good feel for what you are getting into if you decide build a clock of your own. Don't rush this one...save it for when you have a few minutes to savor this charming video.

You may also want to learn how to fix existing clocks, so take a look at Clock Repairing as a Hobby: An Illustrated How-To Guide for the Beginner

Making Mechanical Marvels In Wood - DIY Book

Here's a book that should interest you makers out there. Making Mechanical Marvels In Wood

This book is not unlike Making Wooden Mechanical Models which I reviewed here. There are, however, some important differences between the two books.

Like Making Wooden Mechanical Models, this book isn't specifically written for automaton makers. Both books feature basic wooden machines as finished projects in themselves.

Making Mechanical Marvels differs in that many of the projects in this book are key building blocks to making contemporary wooden automata. For example, projects such as the cam and follower, the Scotch yoke, the fast-return actuator, and the Geneva wheel are all elements often found in an automaton.

The projects in this book are very handsome and would make nice gifts. There's something inexpressibly classy about machines made of wood.

I bought Making Mechanical Marvels bundled with Making Wooden Models from Amazon.com and I'm glad I did. The two books really compliment each other. I consider this book to be Volume 1. This book has very clear instructions and drawings to get you up to speed making wooden mechanisms. Making Wooden Models is equivalent to Volume 2 in which you tackle some more complicated projects.

The book has well-drawn line diagrams and a series of color pages in the center. The instructions are very well written; I would feel good about giving this book to a new woodworker or youngster looking for a science fair project.

The book concludes with some handy shop tips and jigs -- a nice bonus. I have learned a great deal from this book. Don't overlook it as a resource for building wooden mechanism.

Here is where you can order Making Mechanical Marvels In Wood.

Making Wooden Mechanical Models

Not for automata makers specifically -- the mechanisms found in Making Wooden Mechanical Models could well be used for automata, provided the reader has a bit of ingenuity.

The models themselves are nicely proportioned and well designed. Any of these models would be a welcome addition to the desktop of a mechanically inclined person.

I have read this book from cover to cover and browsed the drawings for inspiration. Beautiful color photos in the center of the book demonstrate the skill the authors have great in fabricating with wood. I have found this book to be very useful in this regard. Note: some of the projects in this book are best accomplished with a lathe.

Should you choose to buy this book and make the some of the models, you will find that it contains good project lists and plan drawings from which to work.

Amazon has a nice "Search Inside" this book feature for this book to let you preview the book's contents.

Take a look at Making Wooden Mechanical Models: 15 Designs With Visible Wheels, Cranks, Pistons, Cogs, and Cams.

Easily & Safely Cut Small Parts on the Table Saw

In previous posts, I mentioned the value of having miniature power tools for small scale projects. I find them to be less intimidating and more appropriately scaled for small scale work. They are also great space-savers if your shop space is limited.

But what about using traditional woodworking tools? You may already these tools or want to buy them to work on full-scale home and woodworking projects. You can still cut small pieces on full size tools with some proper planning and helpful jigs.

One such jig is the one shown here. This simple sled allows you to use a full size table saw to rip very thin pieces of stock safely, easily, and uniformly.

The sled is simply a piece of melamine that been ripped to a 10-in. width. After ripping the sled to width, a small block is glued on it to act as a hook to hold and push the material being cut.

Take a look a the full article on the Small Parts Sled from the folks at Woodworkers' Journal. [Thanks Charles!]

Proxxon Rotary Tool & Accessories

I own some Proxxon tools and I own several rotary tools, but I don't actually own a Proxxon rotary tool.

OK..that said, I love the Proxxon tools I do own. Woodcraft is sellng the Proxxon rotory tool at a close-out price right now (about $73). The specifications do sound impressive (see below).

Personally, I am very interested in that Universal Holder (D) for use with a flex shaft (sold seperately). That looks handy, indeed.

From Woodcraft's Site:
Great for detail cutting, grinding and sanding, the German-made Proxxon has a top speed of 20,000 RPM, continuously variable down to 5,000 RPM. Electronic full wave speed control gives almost constant torque, even at low speeds, easing micro drilling. The spindle rides in precision ball bearings, and has a lock button for changing bits. The Proxxon gets its power from a quiet, specially balanced permanent magnet motor. Our own testing showed superior low-end torque and far less vibration than the most popular rotary tool on the market.

Check out all the details of Proxxon Rotary Tool & Accessories over at Woodcraft.com.

PROXXON Mini Miter Saw Model

I own two Proxxon miniature power tools and they are both amazing. Not "amazing for their size" -- just plain amazing.

The mini miter saw is a great addition to any model-maker's or automata-maker's tool collection (or any work area where space is tight). This miter saw is great for cutting 90 degree and 45 degree cuts in a variety of materials. There are detents every 15 degrees for cutting a range of angles.

The saw has a really clever integrated clamp to hold the material and ensure that your cut stays on the mark. There is also a built-in stop to help you cut a bunch of pieces to the same length. Nice.

As with PROXXON Mini Table Saw, these miniaturized tools are clearly not toys; they are solid and exceed one's expectations in terms of performance. Seriously, the mini table saw can make a clean cut in 3/4" hardwood and it's barely bigger than a toaster.

The truly handy thing about owning the miter saw AND the table saw is that they use the same blades. You can get a variety of blades for slitting, cutting wood, and cutting metals. I have found the miter saw mounted with an abrasive blade for non-ferrous metals to be a great way to cut brass rod and bars to length.

Check out all the details on the PROXXON Mini Miter Saw Model and the PROXXON Mini Table Saw

Wood Works with David Marks on Amazon

Amazon.com has recently added Unboxed Videosto its product lineup. What is an Unboxed Video? Simply put, it is a video download of a show or movie that can be purchased or rented and then viewed on PCs, Portable Media Players, or TiVo DVRs.

I did a search and found that season 7 of David Marks' TV series Wood Works is available at $1.99 per episode. For less than two dollars, you can watch an episode on more than one PC or TiVo DVR, keep it in your library, and make a backup disc.

This seem like a pretty good idea: No VCR to program, no tapes to buy or store, and the ability to quickly scan through the video to watch and re-watch particular sections. Each one has a description of the episode, running time, and a short video preview.

If you find other video related to automata, please let me know!

Check out this new online resource to learn about woodworking: Wood Works shows from Amazon Unboxed Videos

Making Mad Toys Book is Now Shipping!

The new book from Rodney Frost (the author who wrote Whacky Toys, Whirligigs & Whatchamacallits) is now shipping from Amazon!

I have not received my copy yet. I will write a longer review once I have it and have had a chance to read it. Here is what the publisher has to say about the book...

Rodney Frost's collection of playful mechanical contraptions will captivate anyone who operates them -- and they'll entice the creative woodworker too, because these whirligigs are as much fun to make as to maneuver. The secret to these movable marvels: propellers and other action-filled parts made from wood or metal. Full-size schematics and drawings, plus detailed written instructions, will guide woodworkers smoothly through building, carving, and assembling many enchanting projects!

Check out Making Mad Toys & Mechanical Marvels in Wood

Master Pocket Hole Jig System - Wood Joinery

Are you inclined to make things yourself from wood, but are short on the skills required for complex wood joints? Are you an accomplished woodworker who just wants a faster way to make a variety of clean joints?

You've got to look into pocket hole joinery. The idea is simple: a jig and special drill bit allow you to drill an angled hole that both pre-drills the wood pieces and provides a recess for the screw head. Special pan-head screws hold the wood pieces together. This technique can be used to make a wide variety of wood joints -- even face frames.

Kreg is the leading brand and they offer systems from $50 to $140 -- all are highly rated. I bought the $50 version and now wish I had the case that comes with the $75 version. Note: you need screws of the right length to match your project.

The basic setup ($50) : Kreg R2 Rocket Pockethole System

The mid-range set ($75) : Kreg K3SP K3 Pocket Hole Jig Standard Pack

The deluxe set ($140, $120 with rebate) : Kreg K3MS K3 Master Pocket Hole Jig System

Woodshop Specialtes: Wood Gears & Marionettes

Here's a book that at first glance might not seem to be of much use to automata-makers, but not so!

There are three sections of this book that are of particular interest to automata makers (and woodworkers in general).

First, there is section on wooden clockworks. This section may only be 8 pages, but it is almost the only 8 pages I've found on wooden gears and their construction. This includes tips on cutting wooden circles, making pin wheels and pinions, and cutting slots for toothed gears.

Second, there are two sections on the construction of wooden marionettes/dolls. Take a good look at the work of Paul Spooner/Matt Smith or Keith Newstead. I would be willing to bet that they studied puppet-making as some point. You can see that they understand the human form, joints, and how to make them from wood.

I have only covered three sections of this book; there are two dozen more on diverse woodworking topics. At this price, Woodshop Specialtiesis a great resource.

Miniature Table Saw - Amazing!

I recently bought some new tools. The first thing on my list was a miniature table saw. My full-sized Craftsman is going strong after forty or more years, but it often seems like too big of a saw for the pieces I cut for automata.

I did some research and bought the Micro-Mark version of what you see here (Proxxon). I am 99% sure that they are made by the same company for every detail is the same except that mine is black.

Simply put, these little table saws are amazing. The saw is very strong and precise. The saw is quite capable of cutting hardwoods and the speed can be adjusted for the material.

There are a variety of blades available including a carbide tipped, diamond, abrasive disks, and fine toothed slitting blades. There are also many fine accessories (rip fences, feather boards, cross-cut tables, tapering jigs) available. I comes with a basic rip fence and mitre slider.

Buying this saw had an added advantage...I was able to free up space by moving my full-size saw out of my primary work area because I need less often.

If you need a good saw, don't have a lot of space, or work with small pieces I think these miniature table saws are a great choice. I LOVE mine.

Check out all the the details on this Miniature Table Saw.

Making Wooden Hinges

Here's a great article from Scroll Saw Woodworking & Crafts Magazine describing how to make hinges out of wood.

The article has complete step-by-step instructions with photos and a scale drawing that you can photocopy and use as your cutting template. The project assumes you have access to scroll saw.

Here's a link to the article: Make Wooden Hinges

Box Joint or Finger Joint Jig for Wood Boxes

I am experimenting with something similar to this jig to make the boxes to hold automata mechanisms. While hand-cut dovetails are the joint of choice, box joints -- or finger joints as they are sometimes called -- offer an interesting alternative.

Box joints are very strong once glued because there is so much surface area for the glue to bond to. I think they look good too because the end grain alternating with the regular grain creates a nice pattern.

I'll let you know how my testing goes. If any of you have experience with box joints or box joint jigs, let me know. This one is used in conjuction with a table saw and dado blade or a router table.

This is one option, the WOODSMITH Aluminum Box Joint Jig at Woodcraft.com

Carving Set with tools, book, and slipstones

Developed for hand or light mallet use, this assortment of tools are made in the USA of high carbon tool steel. They feature hardwood handles with a metal ferrule. Comfortable 6-1/4" to 6-1/2" lengths make them easy to control for detail carving.

Complete set includes the 12 carving tools plus coarse and fine India slipstones, and the popular book "Woodcarving: 20 Great Projects for Beginners & Weekend Carvers" by John Hillyer. Factory sharpened and ready for use.

Here's a link to this Carving Set from WoodCraft. They have many to choose from.

Locate Rockler and Woodcraft Retail Stores

My two favorite woodworking stores sell online and have many retail locations. While shopping online is fun and easy -- handling the tools and selecting your own wood can't be done over the internet. I recommend you find a Rockler woodworking store or a Woodcraft woodworking store near you. Here are some links to help you.

Woodcraft has a great selection of hand tools, especially for carving. In most stores you can handle the tools. They also host courses and demonstrations.

Locate a Woodcraft woodworking store

Rockler specializes is jigs and accessories for you power tools. The retail location near me has a fantastic selection of choice woods.

Locate a Rockler woodworking store

Carving Vise to hold Figures While Carving

Now, I'll be honest...I don't own one of these, but it sure looks like a nice thing to have for carving. I bring it to your attention also because it is on sale for $59.99, normally $71.49.

Adjustable Carving Vise/Carvers Mallet
Two great carving tools! One to hold it and a beautiful mallet to carve your fine pieces! (Mallet head is green not black as shown.) Mallet and carving vise sold separately. Adjustable Carving Vise/Carvers Mallet

Mini Clamp-It Assembly Square Kit

I use these to assemble the boxes that house the automata mechanisms. The squares are thick so that the pieces clamped to it stay flat. The squares are also a strong plastic, so I don't worry too much about marring the wood. They also have little notches in them that allows the clamps to nest securely in them. At $35 they may seem pricey, but I sure am glad I have them, and the clamps can be used for other purposes.

Mini Clamp-It Assembly Square Kit Buy this kit and save $4.95 versus buying individual pieces separately! Includes everything needed to clamp two corners at time; comes with two Mini Clamp-It Assembly Squares and four 4" Mini Clamps. Mini Clamp-It Assembly Square Kit

The Mini Clamp-It can only be obtained in the Tools section of Rockler Woodworking.

WoodCraft Magazine Bundle - Automata Plans

Woodcraft.com -- one of my absolute favorite woodworking stores -- is offering a bundle of the first year of its self-titled woodworking magazine.

This is a great deal for two reasons:

1. You get 7 issues of a great woodworking magazine for $9.99
2. You get Woodcraft Holiday 2005 with my article on how to build a contemporary automaton of your very own. That's worth the price alone!

Check out the Woodcraft Magazine Issues 1-7 Bundle

If you are a hard-core Dug North fan and just want the issue with the automaton plans, you can get Woodcraft Holiday 2005

Dremel 400-3/71 400 Series XPR Rotary Tool Kit

Hechinger Hardware is offering this amazing Dremel package for $105 -- about $30 less than Amazon!

From the marketing literature:
The Dremel 400 Series XPR rotary tool offers the performance, precision and control required to complete the widest range of projects of all Dremel rotary tools--from work, home or studio. Exclusive XPR attachments take advantage of the increased strength of the XPR's unique motor design plus it works will all existing Dremel attachments and accessories.

Look at what you get:

Features XPR Planer attachment, Flex Shaft & Circle Cutter Includes XPR Storage Case plus 71 Accessories in their own integrated storage area Variable speed provides maximum control and precision Permanent magnet motor for increased performance and consistent speed at all speed settings Ergonomic, contoured styling with soft-grip areas for greater comfort and control Lightweight design for comfort during prolonged use Separate on/off switch and speed control dial for the perfect speed every time Lock-out collet button prevents engagement of spindle lock when tool is running "Dove-tail" feature for Dremel-exclusive attachments Cool-running ball bearing construction for smooth and quiet operation Replaceable motor brushes extend tool life Five year warranty

Product Includes:

• 400 Series XPR Rotary Tool
• XPR Planer
• Flex Shaft
• Circle Cutter
• 109 High Speed Cutter
• 150 Drill Bit
• 191 High Speed Cutter
• 401 Mandrel
• 402 Mandrel w/ Screw
• 403 Bristle Brush
• 404 Bristle Brush Cup
• 407 1/2" Coarse Sand Band Shank
• 408 1/2" 60 Grit Sanding Band (2)
• 411 Coarse Sanding Discs (15)
• 414 1/2" Felt Wheel
• 420 HD Cut-off Wheels (20)
• 421 Polishing Compound
• 422 Cone Polishing Tip
• 425 Emery Polishing Wheel (2)
• 426 1-1/4" Fiberglass Cut-off Wheel
• 428 Carbon Steel Brush
• 429 1" Felt Wheel (2)
• 430 1/4" Sanding Band w/ Mandrel
• 431 1/4" 60 Grit Sanding Band (2)
• 432 1/4"120 Grit Sanding Band
• 438 1/4" 120 Grit Sanding Band (2)
• 540 1-1/4" HD Cut-off Wheel (2)
• 541 Aluminum Oxide Grinding Wheel
• 561 MultiPurpose Bit
• 8193 Aluminum Oxide Grinding Stone
• 84922 Silicon Carbide Grind Stone
• 85602 Silicon Carbide Grind Stone
• 932 Aluminum Oxide Grinding Stone
• 953 Aluminum Oxide Grinding Stone
• XPR Storage Case

Wow! This is an entire workshop in a box!

Check out the Dremel 400-3/71 400 Series XPR Rotary Tool Kit

5 Best Books for Making Wooden Mechanisms

Here is my list of the top 5 books for people who want to make mechanisms out of wood. These devices are often used, or could be used, in the making of contemporary automata. The projects are great skill-building exercises and make great gifts.

1 - Making Wooden Mechanical Models: 15 Designs With Visible Wheels, Cranks, Pistons, Cogs, and Cams- Alan Bridgewater, Gill Bridgewater

2 - Making Mechanical Marvels In Wood- Raymond Levy

3 - Making More Wooden Mechanical Models- Alan Bridgewater, Gill Bridgewater

4 - Making Marble-Action Games, Gadgets, Mazes & Contraptions: Designs for 10 Outlandish, Ingenious and Intricate Woodworking Projects- Alan Bridgewater, Gill Bridgewater

5 - Making Working Wooden Locks- Tim Detweiler

Hechinger Hardware

You've got to love their motto: The World's Most Unusual Hardware Site.

You be the judge and let me know if they truly are unusual. I'll scan the site myself this week and update this post with any items that may be of interest to automata makers.

Rockler Woodworking and Hardware

I few days ago I posted about a free Woodworking Catalog from one of my favorite woodworking stores for tools.

Rockler is the second of my two favorite places to buy woodworking tools. I visit their retail store more than any other.

They also offer free catalog. The catalog is 150 pages and offers tons of great tools. They specialize in enhancements for your power tools -- router tables, fences, jigs. The also have tons of specialty hardware.

The thing that Rockler sells that will be of greatest use to automata makers is their line of thin cut wood. They sell planed domestic and exotic woods in sizes that make sense for automata makers.

5 Best Books for Wood Automaton Makers

Here is a list of books for people who want to make an automaton out of wood. These books deal with the subject directly, all have useful patterns, and the first three have detailed plan drawings. I recommend all of these highly.

1 - Automata and Mechanical Toys- Rodney Peppe

2 - Making Mechanical Toys- Rodney Peppe

3 - Whacky Toys, Whirligigs & Whatchamacallits- Rodney Frost

4 - How to Design & Make Automata  - Rob Addams

5 - Cabaret Mechanical Movement- Aidan Lawrence Onn, Gary Alexander

Automata and Mechanical Toys by Rodney Peppe

I have said in the past that if you want to make a wood automaton, and can only get just one book, Automata and Mechanical Toysby Rodney Peppé is the book to get.

This wonderful book is currently available in hardcover at amazon.com for 31% off the regular retail price. This is a great deal.

The book is printed on fine glossy paper and is full of color photos (160 in all). The book profiles over 20 leading automata-makers, and provides step-by-step instructions for making an automata test-bed. There is also a section teaching you how to make ten fundamental mechanisms.

One of the best things about this book is that there are scale patterns to copy and use -- cams, gears, pin-wheels, ratchets, and even a Geneva mechanism.

Visit Amazon and use the Search Inside! feature for Automata and Mechanical Toys

Following as a close second, Peppé's book entitled Making Mechanical Toysshould also interest you.

4" Brass Caliper for measuring

I love the look of this all brass 4 inch caliper for measuring. Often when I use calipers, I don't even read the measurement. Rather, I take the measurement with the calipers on one piece (or tool), then transfer the distance measured on to another piece. Of course, if you want to read a measurement exactly, calipers are a great way to do it.

Some of the product specifications:

• Does outside and inside measurements
• Sliding dovetail way (that's the track in which it slides)
• Rigid construction
• 4"/100mm rule with vernier scale
• Graduated in 1/16" and mm

For under $7 USD, this looks like a very good deal to me. Then again, I love brass.

4" Brass Calipers at WoodCraft

Woodworkers & Carvers - WoodCraft Catalog

Woodcraft Supply is a great store for woodworking tools and supplies. If you don't have a store near you, I recommend their catalog featuring more than 8,000 items. They offer more tools and accessories for woodcarvers than any other retailer I have found.

Not only does the Woodcraft catalog offer a complete listing of products for woodworking, but it's also free.

Get your Free Woodcraft Catalog.

Mini Router Table Bargain @ Amazon.com

As a follow up to my last post, I found this mini router table accessory for Dremel (or other) rotary tools. With the right 1/8" router bits,this tool turns your Dremel into a miniature shaper table for cutting grooves (dado), mouldings, sanding, and edging on small wood stock.

This is looks to be exactly the same as the one sold under the Dremel and Craftsman name, but for much less.

Check out this great deal on Mini rotary table at amazon.com

Rotary Tool Bargain @ Amazon.com

I know I recommend Dremel tools on my site, but I guess I mean "Rotary Tools".

Here is a fantastic deal on Amazon for a Rotary Tool from GMC.

Look at what you get for less than $20:

• Rotary tool
• 40-piece accessory kit and wrench
• 1.2 amp, variable-speed motor (15,000 to 35,000 rpm)
• Lightweight, durable body with soft, rubber grip
• Flexible shaft
• Adjustable mounting stand
• Case
• 2-year warranty

I don't know too much about this brand, but it has great user reviews on Amazon. I do own a bench grinder of this make and it's doing great.

If you buy the Rotary Tool with something costing $5, you will also get free shipping.

Automata Book Store - Huge Update

I've added 45 more titles to the books section of The Automata / Automaton Store that I've set up through Amazon.com. I've selected books on these topics: automata-making, paper automata kits, the history of automata, mechanisms, woodworking, animatronics, autonomous robots, whirligigs, puppets, wooden toys, mechanical toys, wooden puzzles, carving, paper engineering, and the engineering process.

It's basically a reading list to get your Ph.D. in contemporary mechanical automata. I'm less than half way there myself.

Please visit The Automata / Automaton Store to further your education...and my own!

Makers: Gift Card with Purchases at Northern

For those of you that make stuff -- automata or otherwise -- Northern Tool is running a special promotion where you get a gift card with your purchase. Type in this promo code on the Address Verification page: 94660.

The offer applies to orders over $100 bucks, but this time of year, that's easy to do. They have pretty much every tool under the sun from a $2 strap wrench to a bulldozer that goes for $21,800!

Don't take my word for it...see if there is a tool you cannot find at Northern Tool + Equipment.

(If are unable to find a tool, post it as a comment here.)

Wood or Paper Santa Automaton for the Holidays

You may just have time enough to find Woodcraft magazine (Holiday, 2005) and make my exercising Santa automaton.

If that's too ambitious, why not make Rob Ives's paper Santa automaton?

Though it's for sale in Pounds, the amount in U.S. Dollars will come out to about $5.75. Once you pay, you can download the pattern immediately. Open it in Adobe Acrobat Reader (free, if you don't have it already), print it out on some good paper and away you go. This is a great way to keep the kids busy during the pre-holiday -- in school or out!

Visit the Flying Pig page for the Laughing Santa Automaton

Tool Freaks: Northern Tool has Free Shipping!

With the Holidays coming, this is a post you really should bookmark. If you have tool-freaks in your life, Northern Tool + Equipment is a great source for everything tool related. At the very least, you'll want to order the paper catalog.

Visit Northern Tool + Equipment for Holiday tool gifts

Scroll Saw Tips and Patterns

The scroll saw is a great tool for the automaton maker. It can be used to cut gears and cams, as well as the rough shapes for figures. Furthmore, it's a fairly safe and friendly saw for those new to woodworking. Frank Swoboda's scroll saw site has information on the following scroll saw topics:

• What about Wood
  
• Different blades for different jobs
  
• Patterns on the Wood
  
• Still cutting one at a time
  
• Use of wax to cool blades
  
• Which way to turn blades
  
• Stack, Multiple Layers, and turning
  

The site also has free patterns, reference material, and useful links.

Visit the The Scroll Saw Tips and Patterns site.

Here's everything-scroll-saw at Amazon

Scroll Saw Tip - Filing with the Scroll Saw

Scroll Saw Sanding File Turn your scroll saw into a power sander. Silicon carbide abrasive is aggressive enough to cut as well as sand in most materials... Scroll Saw Sanding File

Hardwoods for Toy and Automata Making

Here's a link to a brief guide to American hardwoods. I've used many of these woods in my automata. The Birthing Engine box was made of Alder. In my other automata I have used Cherry in one way or another -- boxes and parts. Cherry is stiff and strong, though it's fairly easy to burn.

Here's a link to the The Brief Guide to American Hardwoods.

You could also check out the listing of Thin Lumber-Exotic and Domestic on my resources section

Feel free to list more species or wood resource links here.

Automata Book Store

Announcing: The Automata / Automaton Store powered by Amazon.com. I've teamed up with Amazon.com to give automata enthusiasts an easy place to find books on automata, mechancial toys, wood toys, mechanical reference books, and paper automata kits. It has been set up to display some of my favorite books on automata and mechanical toys.

Visit and bookmark The Automata / Automaton Store

Automaton Hardwood Links

I've added a big section to www.DugNorth.com in the Materials section under Resources. You'll find a full list of links for hardwood for your automaton project, jewelry box project, figure carving, or other small woodworking projects.

Here is the Materials page on DugNorth.com.

Solvent Transfers for Cutting Wooden Gears or Parts

Here's a method for transferring patterns to various surfaces -- including wood. Called "solvent transfer", you use a photocopy or laser print and solvent to transfer the image to the wood. I've been doing this for about a year now. Once you get the hang of it you can transfer detailed cutting patterns to wood very accurately. This is a great technique for scroll-saw projects. The results are much better than carbon paper and tracing. Two important things to keep in mind: 1 - Lacquer thinner is nasty stuff so where gloves and do it in well ventilated area. 2 - If your pattern isn't symmetrical (like a gear), you must reverse the image before printing.

Here's a how-to on solvent transfers

DIY Wooden Gear Cutting Indexing Jig

Here's an ambitious and clever woodworker who made his own rotary indexing mechanism to cut large wooden gears on his table saw. He's combined parts from a 1940s remote servo, a car odometer, his own wooden box, a calculator, and a lot of ingenuity.

It's a lot of work, but an impressive result. There's other cool woodworking related stuff on Matthias Wandel's site.

Here's the link to the Wooden Gear Cutting Jig project page.