Replacing a Gear, Part II

I finally got the 3D printed gears. Even though the 3D printing company's software warned me about the tooth size possibly being too fine, I tried it anyway. The teeth did not print correctly, and part of it may be my choice of nylon for the gear. Oh well, sometimes it takes a couple iterations to get things figured out. The bore for the gear was a square, and that seems to have turned out ok. I might cut off the rest of the gear and use the shaft if I can find or make a replacement gear.

I'm not having much luck finding a gear of the exact specs of the old one. It's a small gear, .3 mod, 28T, PCD of 8.4mm. Checking the NWSL catalog, I see several 26 tooth gears listed but no 28T. That doesn't mean it's not available, just that it's not one of the most common sizes.

I may try cutting the gear myself. The trouble with this approach is simply needing the right tooling to do so. Even with a lathe and mill, you still need the proper cutters.

I have no idea when the next installment will be or what the result will be.