A kinetic gear sculpture

The Vision
This artwork, titled DRIVER, is a kinetic sculpture. It is six by fifteen feet, and is installed in the ceiling of a vintage train car.
The inspiration for this project is a train car. A couple of our good friends are part owners in Sky Railway, the train that entertains riders on the way from Santa Fe to Lamy and back. We got in a discussion over beers about an antique train car that these guys bought. It needed an overhaul and interior update, and I agreed to go take a look to see what the story was. What I found was a very cool old car, made in the 1920s, that was divided into two parts: a larger area with no seats and neat wood windows and trim, and a smaller mailroom/baggage room. The car had evidently been painted and fixed up by a movie crew, so the interior was in good shape. I worked up a design for the whole car where the main area would get bench seats along the walls, and red plush upholstery with red leather, red carpeting, and gold trim/fixtures. The mailroom had a very steampunk vibe and so I proposed putting a kinetic gear sculpture in the ceiling. Eddie Peck, the Sky Railway CEO, took my design and, while keeping to the aesthetic I presented, designed and built the seating and tables, adding a few of his own ideas to the mix. Meanwhile, I was commissioned to build and install the gear sculpture in the mailroom that was now the bar area, and do the bar facings and some tables, interior painting, wall sconces, and a screen to hide the big air handler that was installed over the entry door. It is a big deal to get a train car like this up to a usable state. It needed new wheel trucks, new heating and air conditioning systems, bathroom facilities, fresh water tanks, and a power system. And the completely new interior. Eddie did a fine job getting this together—doing a bunch of the work himself—and it is a very nice car and a great addition to the Sky stable of rail cars. Skyrailway.com

The Process
The armature of DRIVER is made from 3/16″ steel plate.
I wanted three big gears to look massive and super heavy without any of that actually being true, so I constructed them from thin metal sheet with a three inch reveal or vertical dimension, and no top face. They appear to be solid, but they are not. The five foot gear in the middle weighs maybe 125 pounds. If it were solid steel, it would weigh 800-900 pounds. The big gears are mounted to trailer hubs which are inexpensive, easy to come by, and very strong and reliable. All of the gears and connecting shafts were fabricated by me in my shop. Clarity did a lot of work shaping 150 gear tooth halves, and a lot of the finish work to get the surface treatment I was after. We called in a couple of folks who have helped install on other projects, and the four of us installed the thing in a morning.
You can see pics of this part of the process in the gallery section below.











