I just built one this year. The biggest problem seems to be getting the wood gears accurately cut. However, I looked up two suppliers of Steampunk gears and asked them if they could do custom work. Both had laser cutters. One of them was glad to do a custom order, and I got both gears beautifully (and effortlessly) cut for a total of $40, including material (which he bought from Windfield) and shipping. Was WELL worth it. HOWEVER, even though they were made of hardwood, wood in general, as you know, expands and contracts. Often, there's grinding noises when it starts up until it runs for 1/2 hour to 45 minutes. I am not really satisfied with using them, and plan to replace them after the season with metal gears. I notice that wood gears often have that shape on the spokes, but I haven't seen metal gears that do, and now I'm trying to find out if I can substitute the shape of the teeth. I know of a supplier of custom metal gears who can do this. Here's the expired listing, and you can message him. By the way, I spent about $220 for wood. You might want to rethink the scallops on the wood that supports the seats. It's only decorative, and if I had to do it over again, I wouldn't have gone to the trouble.
http://cgi.ebay.com/ws/eBayISAPI.dll...d=834314009022
As to the motor. I bought the motor kit, and so far the motor has been holding up. However, I had been told that their motors can be unreliable, and I have already looked up a motor that has the same specifications and foot print by Dayton. It is the Dayton 2L008, a permanent magnet gearmotor, 12 RPM, 40 lb./in torque.
Hope this helps!
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