Great information Brian,
I've taken it all in I appreciate your photos as well they tell so much thanks.
I did cut gears in my fitting and turning apprenticeship a long time ago will have to retrain.
Good stuff ifredaj.
Disaster!! one day after posting.
Andrea the 11 year old lad who is making this clock returned to the shop to finish this wheel, and at one point he forgot to turn the sector arm on.
The groan could be heard for miles,Not a happy lad, even less happy when i told him to go 1 tooth back and then finish the job.
I felt It was cruel to take photos At this point .
I set up a small end mill and cut out the bad tooth to twice its depth. (This did not help the lads composure)
I cut a piece to fit the gap but left a handle on it so I could controll it, Tinned the mating surfaces and soldered the plug in place with a small gas torch.
At this point the discoloring ,solder etc, got to mutch for Andrea and he left the shop in dispair.
The gear cutter was replaced and indexed and zero'd on a good tooth , then moved into position, light cuts where
taken until the depth read zero, the wheel removed and cleaned up
I took it to Andrea so he could get a nights sleep.
I cut gears either on the mill or the lathe, I prefer the mill but care has to be taken when transfering the blank from the lathe to the mill. I have DRO's on the mill it helps a lot!
If you need more info feel free to ask.