[Cory]

I would strongly recommend reconsidering this approach. Your rookie year is hard enough (even if you have some experienced mentors). Don't screw around doing something exotic you've never done before. Get COTS gears. Modify them if you really need to.

You will not be able to mill or waterjet a true involute tooth profile. If the gears in question only mesh with each other, an approximation would be fine. The best way to do this yourself is to get involute tooth cutters for the mill and a indexer so that you can cut them. This requires a series of cutters to cover all possible tooth sizes.