Art, when reaming on the lathe, make sure your tailstock is aligned horizontally with turning axis. It wouldn't be a bad idea to check vertical height of the tailstock as well. Slow speed and sufficient cutting oil. In addition, if you don't have a collet chuck to fit the OD of the gear, you can make an adapter bushing slightly undersize to the gear OD (push fit) and cut a slot from the external diameter into the interior bore. Then you can hold it in your 3-jaw chuck without damaging the gear teeth. This will also serve to help face the gears when you cut them from the gear stock.
