This is a remix of the awesome iPhone 5 gear case by Brandonw6, which in turn was derived from the awesome iPhone 4 gear case by QuentinT.
I've redesigned the case to make it thinner and eliminate the seam along the side. It is now 2mm thinner all the way around, and 5mm shorter. And no seam :) If you had previously downloaded or printed this case, you might want to re-download and check out the changes.
The pins were widened a bit so they fit properly, and the 35-tooth Geneva driver gear was modified to mesh properly with the Geneva wheel. This was tested with PLA on a MakerBot2 and worked great at standard settings (see picture). Please see instructions for printing and assembly comments.
Print the case back and the case frame horizontally with rafts; I put "ears" at the ends to eliminate warping. You can print all the gears and all the pins at once, also with a raft. (Depending on what color combination you want, you might do multiple prints!)
The case back fits tightly inside the frame; you might have to sand lightly for a perfect fit. Press the case back all the way up against the little stops at the bottom of the frame. Make sure the flat side of the case back faces the "inside" of the case, where the phone will be, and that the camera hole in the case back is just below the notch for power button. After the back fits snugly, superglue all the way around the seam between the back and the frame on the back side, where the phone will be. After this dries you can test the fit with a phone.
Next fasten all the gears to the eback by pressing their pins through the gears and into the back. You might have to scrape out the holes in the gears a little with a knife. The pins should be pretty tight; usage will loosen them up. After all the gears are inserted, test the gear meshing by lightly turning with the gear chuck. Make sure the pins are pressed all the way into the case back. When all is well, put a drop of superglue on the back of each pin.
That's it; insert your phone, and enjoy!
*I've uploaded Makerbot thing files with ears for the case back, case frame, all gears, and all pins.