Create two circles that will be the eyes. Make sure that they overlap in the center. The eyes will be gears that can rotate. Instead of cutting them on the mill, we will cut them on the plasma cutter. I made the outer circles for the eyes 2.25' in diameter. I dimensioned the left eye 3' away from the left edge of the stock and 2.5' from the top edge of the stock. Mirror the eye across the center. Now make a smaller circle on the inside of each eye. Be sure that the inside circle does not touch the edge of the opposite outer circle. This will be the base circle for the gear. We will make a separate drawing file for the eyes, but you need to see how big they eyes will be to determine the features of the body. Make a new drawing file for the eyes. Copy all of the drawing file aspects of the circles on the body onto the new drawing file. Next make a line facing out of the inner circle reaching to the outer circle, as the left side of the gear. Mirror this across, now you have one tooth of your gear. Copy and revolve this around the circle so that there will be teeth around the gear. I made 10 teeth on my gear because that will allow space between the teeth of the gear for the opposite gear teeth. The eyes will be cut out on the plasma cutter like gears so that they will spin when you move them with your hand. BE SURE THAT THEY OVERLAP IF YOU WANT THE EYES TO SPIN!!! We will be using a 1/4-20 bolt to attach the eyes to the body, so make the holes in the gear slightly larger than .25'. Mine are .275. For the holes in the body, make them .20'. They are smaller than .25' because that is the size of a 1/4-20 hole pre-tapped. We will be tapping these holes for the bolts that hold the eyes onto the body.
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