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On the gear detail...
I have a buddy with a desktop laser cutter. He can cut wood, phenolic, and non-PVC plastic (I think), but no metal. Runs of a CAD/CAM file. It's in a community/membership-based shop in Columbus. If the teeth are not too fine, I believe he could cut one of those in pretty short order.
I realize you've engineered a good solution, so you're no longer needing a replacement gear. But is this a common need out is resto-land? And do you think phenolic would hold up to the tuning duties?
(There are many of these community shops out there, too.)
Chip
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