Bevel Gear

The bevel gear changes the direction of a

turning movement. This working paper
mechanism gives you all the parts you need as
well as clearly illustrated instructions to make
your own bevel gear mechanism.
Let the turning begin.
© Rob Ives / Flying Pig 2005
www.flying-pig.co.uk

ver. 1.02
 Instructions
You will need a craft knife or other sharp knife, a pair of scissors, some glue
and a glue spreader.
The best type of glue to use is white school glue (PVA.)
First of all print out all of the parts sheets onto thin cardboard. Photocopier
card is ideal. Leave the ink to dry completely before continuing. Dashed lines are Dotted lines are
Before cutting anything out, score along all the dotted lines and cut out any hill folds valley folds
holes with a craft knife. Both these jobs are easier to do on full sheets of
card.
Dashed lines are hill folds, dotted lines are valley folds. Cut along the solid Cut
lines. Grey areas show where to glue. out

Black lines show Shaded areas show

where to cut. where to glue.

1
Both gears are constructed
in the same way.
Start off by cutting out the
gear former and the teeth.
Glue the teeth to the former,
use the coloured lines for
alignment, line up the
coloured line on the teeth
with the line on the former.
The sixteen tooth gear uses
red lines and dots, the
eleven tooth gear uses blue
lines and dots.

2
Fold the gear former round
and glue it together so that
the teeth butt up against
each other.
Fit the gear top into place
from the back of the gear.
Don’t glue the gear base in
yet.
Repeat this process for the
second gear.

Bevel Gear Instructions 1

 3 4
Sixteen tooth gear (Red)
Assemble the shaft.
Slide the washer into place
and glue down the tabs.
Glue the gear base into place
on the shaft.
5 6
Repeat the same process
for the eleven tooth gear
(blue).
Notice that this gear is
effectively upside down
compared to the red gear.
7
Assemble the handle in
three steps.
Glue the two square
sections as shown.
Bevel Gear Instructions 2
Slide the previously
assembled sixteen tooth gear
(red) into place and glue the
flaps top and bottom.
Make sure the gear is straight
on the shaft!
Glue together the box
top as shown in the
picture left.
Glue together the
box base as shown
in the picture on the
right.
Fold the two Fold the long flap
square sections round and glue into
into each other place.
and glue.
 8

Turn the box upside down.

Thread the sixteen tooth gear
(red) down through the hole in
the top of the box.
Fit the eleven tooth gear (blue)
into the box through the two
holes in the side of the box.
Use the grey area on the blue
shaft to show where to fit the
shaft washers.
Glue the base of the box into
place on the bottom of the box.
Washer

...and finally.
Thread the box upper
down over the vertical
shaft and glue it into place
on the box.
Glue the handle to the
horizontal shaft using the
grey areas for alignment.
Assemble the two vanes
and glue them to the
vertical shaft.
the bevel gear should now
be ready to go!

Bevel Gear Instructions 3

 Handle
Washers
Cut

Cut
out

out

Box

© Rob Ives / Flying Pig 2005

www.flying-pig.co.uk

Cut out Cut out

Bevel Gear Parts 1 © Rob Ives / Flying Pig 2005

www.flying-pig.co.uk
 Eleven Tooth
Sixteen Tooth Sixteen Tooth Gear Top
Gear Bottom Gear Top

Eleven Tooth
Gear Bottom

Bevel Gear Parts 2

Box Top

Box Bottom
OUT
#UT
 Vanes

Sixteen Tooth Eleven Tooth

Gear Former Gear Former
Sixteen Tooth Gear Teeth

Eleven Tooth Gear Teeth

Bevel Gear Parts 3

 Box Upper

Cut
out

Eleven Tooth Gear Shaft Sixteen Tooth Gear Shaft

Bevel Gear Parts 4