There are several options for fabricating the crank wheel. The simplest might be to cut the shape from 1/4" plywood using a jigsaw. In this case, I thought I'd take the opportunity to explore some of the different free toolchains that are available for solid modeling of 3D printed parts. I designed the part first in Autodesk's 123D, then in Trimble's Sketchup, and finally in OpenSCAD.
First (upper) and second (lower) version of crank wheel |