I have a gear cluster away being shaped at the moment, is a fairly tight stack of three gears about 1 inch spacing between tooth flanks and the center gear has rounded teeth to aid shifting. (Its from the norton box of a DSG) The gearcutter does not have a tooth rounding machine and their VMC has backlogged work for ages so im going to have to do it either by hand (Unattractive as its tough material and i dont want to scuff all the teeth faces up)

Or look for a manual mill setup. I was thinking of using a dovetail cutter or woodruff cutter to just nip in there on each tooth the only downside is the rounded end would be a flat face rather than smooth curve but i dont see that being a huge problem.

its a cluster of a 26, 24 and 22 tooth 10 Dp gears


Read the full thread at metalworkforums.com...