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Originally Posted by Matt Reiland
As for mounting the piece, I would probably not use a vice but instead hold the piece flat to a table with screw down clamps out on the edges, this would put very little stress on the teeth since you are clamping through the meat of the gear. You should be able to get far enough out that you can mill all you want.
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This is how we do it, and it has worked fine for us in the past.
Combined with a way to place consecutive gears on the same center (such as the method Matt mentioned above) it greatly decreases the setup time necessary.
JV