Supplies Needed:

• Cutting File from 3dcuts.com
• 8.5 x 11" card stock - gray
• Permanent Paper adhesive I used:
• Scotch Tape Runner
• Spray Glue (Aileen's Tacky Spray)
• Tape Adhesive (Scor Tape)
• Scotch Quick Dry Adhesive

Part Sizes:

• Note- measurements are based on the orientation of a file as imported. If you rotate the gears the measurements will no longer apply.
• Steampunk Gear Large - 9 tooth
  • Gear and gear coverings - 8.1425"w x 8.0205"h
  • Gear center cover - 5.197"diameter
  • Gear tooth outside wall - 4.2959"w x 1.75" h
  • Center hole side wall - 4.056"w x 2.152"h
  • Slot side wall - 6.9602"w x 1.736"h
• Steampunk Gear- Medium - 7 tooth
  • Gear and gear coverings - 6.3867"w x 6.5498"h
  • Gear center cover - 3.3845" diameter
  • Gear tooth outside wall - 4.3616"w x 1.75" h
  • Center hole side wall - 4.1346"w x 1.7361"h

• Apply the adhesive to one side of both gears with extra holes. Place them sticky side and proceed with care. You don't want then to accidentally stick to random paper surfaces! Keeping the sticky surface free is the most challenging part of this assembly.

• The gear will be assembled from the center out.

• Roll this up so it will slide into the center hole of one of the sticky gears. 
• Position it so the tab of the cylinder will be on the outside of the cylinder and not show in the center hole. When the gear is finished the interior of the center hole is visible and the outside of that cylinder is not. 
• Once inside the hole, you will be able to judge the exact size for this cylinder.
• Peel the backing tape off the Score-Tape only on the cylinder tab and press in place being carefully to keep the seam square to the edges. You want the cylinder to have the same diameter at both ends.

• Slide the second sticky gear onto the center shaft (adhesive side facing out) being careful to watch for alignment of the spokes of the wheel. (No spokes in small gear.)
• There are 3 spokes and the two sticky wheels must be placed on the center shaft so these are in alignment.
• Do NOT fold over the tabs of the second end of the center shaft until  you have positioned one side wall of the slot to help with this alignment. (next step)
• You may fold over the tabs on the medium 7 tooth gear at this point and skip step 7- Prep and install slot Side Walls. Move right to step 8 because the medium gear has no slots.

7. Prep and insert slot side wall. (Skip on medium gear)

• There are 3 side wall pieces that match. These are for the side walls of the 3 slots.
• Fold along the 4 cross-wall fold lines as shown in the diagram. One side is noticeably shorter.

• Slide the slot side wall into one slot of both layers of the sticky gears. Use the slot side wall to help align the spokes between the top and bottom sticky gears.
• Fold over all tabs on one side of the slot wall and stick into place. Fit is important and take your time to line things up.

• Remember as you work that the side walls will show on the finished project but the flat surfaces will not.
• Here I noticed some spots that didn't have good adhesive coverage. I simply added a drop of Scotch Quick dry adhesive and held it for a few moments to hold tabs in place.
• Be careful to not get glue on the visible surfaces though.

• Now that you are sure the spokes are lined up you can bend over and adhere the tabs of the other end of the center cylinder.

• Repeat step 7 for the remaining two slot side walls.

• As you work some of the tabs may tend to become unstuck. Keep pressing them back in place. 
• If you have some stubborn areas it is fine to add a little scotch tape to hold them in place.
• I used regular scotch tape cut in half, and applied tabs in places that needed extra stick.
• Don't allow the tape to hang over edges. It will show.

• At this point your gear should be starting to feel a little more solid and it gets easier to handle because there are an increasing number of surfaces that aren't sticky.
• All 3 slots should have side walls. The center should have a side wall and all tabs should be glued down. 
• As you start adding the walls to the gear teeth you will lose access to these areas.

8. Prepare and insert the gear teeth side walls.

• (Medium Gear assembly directions resume here.)
• There 9 gear teeth on the large gear and 7 on the medium one. You should have cut the matching number of side wall pieces.
• Fold one to resemble the folds to the right.
• All folds are in the same direction except for the last two folds on the end with the glue tab. Those fold in the opposite direction.

• It is easiest to position the gear tooth wall by starting at the base of the tooth and placing the longest piece in position at the bottom of the notch. 
• Fit this section carefully making sure it is seated all the way down into the notch before adhering the two side tabs. If your fit is poor on this piece, the entire tooth will not fit well.
• Press the side tabs firmly in place on both the front and back sticky gear.

• Position each facet of the gear tooth side wall, one tab at a time moving out along the gear tooth, across the top and down the other side. Adhere both the front and back tabs. Press firmly in place while you have access to these tabs. Access will become more limited as more wall is attached.
• The outside edges of these gear teeth will be visible when finished so keep them clean.

• The round holes in the gear are there to provide you with inside access. Using a pinky finger you can reach in to help apply pressure to tabs from the inside.

• Prepare the next gear tooth side wall by folding in the same way as you folded the first (See 8 above).
• Apply Score-Tape adhesive NOT to the tab but to the inside of the last panel at the end OPPOSITE the tab. This will adhere to the previous tab.
• Peel the backing tape

• This panel that has the Score-tape on its back side will get positioned over the tab at the end of the previous side wall you put in place.
• Align it carefully making sure it is snug in the corner and press in place.

• Again, position each facet of the gear tooth side wall, one tab at a time moving out along the gear tooth, across the top and down the other side. Adhere both the front and back tabs. Press firmly in place while you have access to these tabs.

• Continue around the gear adding teeth.
• Notice in the photo some of the tabs are coming up. I just kept pressing them down or adding tape if needed. The final steps covers all of those to hold them in place so they aren't a huge worry as long as things are secure.

• The process for inserting the final gear tooth side wall is a little different.
• Put tape adhesive on the top of the tab in addition to the tape adhesive on the backside of the last panel.
• Peel both. The tab gets slid behind the end panel of the first wall that went in and pressed in place, and then position the panels around the tab and press the other end in place.  

• Go back an press all the side tabs in place.
• Inserting your pinky into the holes to gain access to the underside and apply pressure is helpful.

9. Apply Gear sides.

• Use spray adhesive to cover one side of the gear side covering with adhesive. I like to use Aileen's Tacky Spray adhesive because it takes about 30 seconds to dry leaving you a little time to slide a piece into place.
• Repeat on the flip side.

• Also using spray adhesive adhere the center cover. This overlaps the edges slightly so if your placement of the side walls wasn't perfect it will help hide some of the tab edges.
• Repeat on flip side.