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Re: Backlash
If you really want to learn what the right demensions are use a machine design book (norton or shigley) or you can buy an old machinist Handbook. Since you are using spur gears any old addition should have the right info.
As far as tolerance goes, almost any mill that has functional lock on it can hold a tolerance tighter than 0.005 learn how to work against slop and practice.
That being said our team made AL side-plates for an AndyMark gearbox. It took two tries. The first shot I merely explained what to do with the students. They made a couple big set-up errors and the plates wouldn't work. I worked closely with them to make the second set and it worked out better.
Rule of thumb on press fits 0.001" per 1" diameter. This has almost always worked for me in the past. Gearboxes are a good test of skill. They hate being too tight and will destroy themselves if too loose.
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