It was just one document Barry, loaded up twice for some strange reason.
emachineshop? Hmm, I think I would rather present a pattern to the machinist myself. I would be sure to make a mistake with the software and then end up with an expensive part that didn't fit.
Cheers Bob. I didn't realise we could post pdf files.
It would still be good to see some photos. You must have investigated alternative solutions, not just the dynostart. Something in between perhaps?
If the gears were separate 'pressed-on' parts etc. it would be helpful.
The idea would be to draw up the gears in 3D CAD then make SLA rapid prototypes to see if all is well.
These rapid prototypes may be suitable for use as casting patterns but castings may not be tough enough?
The CAD could be supplied direct to the machine shop - Jims contact or others.
I am still a bit worried about the specification of the metal and the hardening required.
All this is quite a bit of work $£$£$£$.
An alternative solution could be cheaper and easier but I suppose the original designers thought theirs was the best idea.