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Originally Posted by sanddrag
I tend to think the sliding friction and wear of the gears on the shaft isn't.
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So your saying dogs don't wear on the gears either?
Milling the four slots into the gears with a mill bit is easy. Slap the bored out gear on the mill vise, dial indicate it on center, move the table to each slot, and your done. (If you have a digital readout lucky you!)
We do not have access to this wire EDM you speak of!
These transmission can be built with a mill and lathe.
The tolerance is usually about 4-5 thousands. In other words, if your shaft was 1.000'' you would bore the gear diameter out to 1.004'' I do believe we have made that gap as much as .01''