I've just had an update from the supplier of the gears for the axle hung motors and we've hit that problem that comes from only wanting a low production run, rather than thousand of gears, which would be a doddle. For definitions of doddle that mean having enough capital to invest in an injection moulding tool being made.
So it is back to the drawing board for this. There is a solution, but as the old adage of cheap, fast, quality, choose any two applies.
You will rarely hear me suggest this path, but 3D Printing maybe the best option for you. Find a friend who's good with CAD and have at it.
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Upon further reflection, try and find an old codger with a small machine shop setup and get him to cut your gears in brass. Surely there's a few still left with the talent.
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