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Re: how thin is too thin?
Might depend on the material you cut the gear from, and the orientation of the keyway w.r.t. teeth. Stress will concentrate near the corners of the keyway. Since your tooth pitch along the 8mm bore is 8*pi/17 ~= 1.48 mm and the keyway is 2 mm wide, you cannot avoid putting the stress in a thin area. Do you have enough axial space to include a hub on your gear?
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Richard Wallace
Mentor since 2011 for FRC 3620 Average Joes (St. Joseph, Michigan)
Mentor 2002-10 for FRC 931 Perpetual Chaos (St. Louis, Missouri)
 since 2003
I believe in intuition and inspiration. Imagination is more important than knowledge. For knowledge is limited, whereas imagination embraces the entire world, stimulating progress, giving birth to evolution. It is, strictly speaking, a real factor in scientific research.
(Cosmic Religion : With Other Opinions and Aphorisms (1931) by Albert Einstein, p. 97)
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