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Originally Posted by Cory
gears don't have any 90* angles except for the face of the edge of a tooth.
It's not going to run under load at any rate, so they don't need to be perfectly precise.
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but if its not a good fit you get serious probles. for example a section of the gear isnt close and it pushes on other gears. it could case a jam, wear, or chipping. with most drivetrains you want close to perfection. look all i know is that you dont use a waterjet to cut gears and this doesnt just come from me.