Issues Cutting Small Spur Gears

You might want to look at grobinc.com. They do gearbars in many different materials and stock a good deal of material on hand as well as do custom work. I have used a few feet of their product, and can vouch for its quality. They are more reasonable in cost than the more common gear shops on most stuff. Worth a look anyway.
 
Thanks for all the options, will give them a call and see what they can do.

I got my hands on some wires and measured .. all of the gears that "look" bad by eye are consistent around their diameter with wires - but vary between separate gears.

I am waiting for this book to get here ... then should be able to get a solid plan in place: http://www.powells.com/book/gear-ha...acture-application-of-gears-9780070179028/1-7

And then there is this video that does a nice breakdown .. first time i`ve seen anywhere that you should add that backlash variable:
 
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