Here is some final documentation of my building process.

Testing the circuit:

Building Process:

My first prototype was made of scrap 3/4 plywood.  I used the CNC Router to do a test cut of my gears.  The rest was thrown together with any available wood and screws.

Moving on from the prototype I designed a two level box to house my coils.  The coils themselves remained in their packaging.  I soldered the leads to wire and cut acrylic tubes to size and added rubber end stoppers to house the neodymium magnets.

After staining the wood to a walnut color and drilling holes for all my wire I gave my box a tolex covering:

I also created a separate housing for my soldered bridge rectifier circuit:

This circuit uses a series of bridge rectifiers to  convert the alternating current (AC) of my coils to direct current (DC):

The beginnings of the synth circuit and interface:

Look closely to see the synth circuit, the optional capacitor circuit, and the bridge rectifiers.  Springs are mounted to the box.

The synthesizer circuit consists of 3 integrated circuits (IC) in series.

The 74C14N oscillator provides input for the CD4093 which in turn becomes the input for the CD4040 

Using the CNC I cut my pedal, baseboard, and under pedal connectors from 1/2 inch plywood.  I put sleeve bearings through all bores that house moving parts, and shaft collars to help keep moving parts in alignment.

CNC cut box to house the synth:  Note the massive scratch, an error in either CNC file setup or in zeroing the CNC.  Luckily for me this error is cosmetic and will be covered up.

I also added an acrylic cover to my coil box

Synth circuit soldered and mounted to the faceplate
Synth with tolex exterior and laser cut luan face plate.  Buttons were numbered to match the outputs of my CD4040 IC:

Final assembly
Power inputs for the synth and the mounted speaker

Switches for the Pedal’s capacitors
Speaker power source switch

Outputs for Headphones and speakers.  A switch to alternate between the outputs

Tone buttons for the 4040 chip

Photo-resistor & “GLITCH” switch controlling my 4093 IC. Oscillator Potentiometer controlling the 7414C IC.  Mounted speaker.

Watch it go!

Here is my presentation for my Pedal Powered Synthesizer

Pedal Power Synth

(skip to the end for circuit drawings and stats)

My Geared Pedal Mechanism Works!  The circuit is generating sound and power, however I am still connected to an external amplifier and need more power to drive my speakers.