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Originally Posted by Tristan Lall
You're welding some of the gears, I see. I'm not a fan of welding, because it can make disassembly a great pain. I'd recommend keyways if possible. (Consider adapting the design for keyways; despite the initial difficulty of putting them in, if you lack a broach, they're very precise and easy to work with.) If you do weld, make sure that the materials are compatible!
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Also, the key way option lets the gears stay intact in a high stress situation. In situations like that, the gears teeth will break faster than the weld will, so if you have a couple spare boxes laying around, I would weld them, but keying is much more reliable and easier to change in a breaking situation.
That is one reason we don't weld gears onto shafts anymore.