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Hi Did a quick search on the old googler and found these guys http://www.newcastlefoundries.com.au/ (Disclaimer I have no connection with the company in question.) Maybe a donation to the beer fund would render you a bag or two of casting sand? Could be worth a try.

That is so lovely!

Wow, that is absolutely gorgeous!

Now I'm confused. I've been using this for years with satisfactory results: http://www.micro-machine-shop.com/module_gear_data.pdf

In addition to what's allready been mentioned about using the correct cutter, based on the picture it looks like you might be cutting the teeth too deep. To calculate the cutting depth we multiply the module of 0.8 with the magical number of 2.157 which gives us 1.7256mm, lets call it 1.73. So...

Denatured alcohol works wonders for aluminium. Dirt cheap and works every bit as well as WD40. As a bonus it doesn't leave any residue on the workpiece, if anything it comes out cleaner than it got in.

But surely it must be possible to source it locally? Here in Sweden you can buy it in any home improvement store. It's used as a cement and concrete sealer.

Wow! That is gorgeous!

Any metal with a similar specific density to bronze will do. I used cast iron instead of bronze for the flywheel rims. Cast irons specific density is roughly 85%-ish of bronze so rims were made slightly oversize to compensate for the lost mass. There are two other parts on the Hoglet that can...

Happy to help. I made my own chain cogs. The one on the kicker end was drilled, bored and then carefully hand reamed to 10mm with a slightly worn reamer that I know won't go oversize. If I remember correctly the bearing is 0.01 or 0.02 mm oversize which provided for an excellent press fit. No...

Having almost completed a metric version of the Hoglet, I had to make my own gear and use one of these: http://www.ebay.co.uk/itm/HF0612-One-Way-Bearing-10mm-x-6mm-x-12mm-Needle-Rollers-NEW-/141166409759?pt=UK_ToysGames_RadioControlled_JN&hash=item20de2c781f With a 0.02mm pressfit.

For us non UK europeans: http://stores.ebay.co.uk/Screws-More

Here's where I get mine... http://www.dealextreme.com/p/gp-lr44-a76-1-5v-cell-button-batteries-10-pack-3032 And free worldwide shipping to boot.

The is a classic argument on the subject... Metric vs. Imperial or Will the USA ever go metric? Ladies and gentlemen, we are here today to determine the United States measurement challenge once and for all. In the blue corner we have our current US champion for many years, weighing in at...