I agree gears would be cooler to have in this gearbox, but the only machine we could attempt making gears with is the CNC Mill and with limited knowledge on how to use it, the gears would be difficult to make.
The other problem with gears is that it would probably be difficult to see inside were the shifting occurs, this too may also be a problem with just "wheels" in their place.
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How ever that pneumatic shifting set up is kind of a Kludge.
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Are you referring to the 2004 three speed or the 2005 two speed shifting setup?
We thought about using servos, but we just had too many problems with them in the past when using them to shift the drill motor transmissions.
Not sure exactly what you mean by cutting the cylinder at an angle?