Pics of the RMD-3 laminated maple veneer gear.
Last 2 pics are the clamping form. Made from 2 layers of .75" MDF, about 8" x 12" each.
Cut profile of gear on bandsaw (you need to allow for a little spring back when it comes out of form).
2 each .75" x 1.5" maple boards on top & bottom extend past the sides for the 3/8" all thread & wing nuts for clamping.
5 layers of maple verneer .020" each, brush on 30-min. epoxy, clamp in form overnite.
I wax the form and wrap lamination in wax paper to prevent sticking.
Veneers are thin enough that no steam or wetting is needed.
Cut taper of the gear leg on bandsaw after it comes out of form.
5 layers gave about the right spring and strength for a 48oz plane.
If it was 60 oz plane I would add another layer and / or use a layer of glass on each side.
Will put full res pictures on Brotherhood of the Ring site in my album titled "perretar", including a couple more of the items Ty mentioned.