Gear Teeth Clearance

[asid61]

Originally Posted by C.Lesco

We'll Show you WE'LL SHOW ALL OF YOU.

See you at worlds

With love: 5870 <3

Listen to the smart people above.
To get gears that are as accurate as any COTS Vex or Andymark gear you would need involute gear cutters.
CNC mills would need a tiny endmill to do gears, and waterjet is inaccurate and has an extreme taper. If you buy a COTS gear, the two pitch circles should be tangent to each other exactly. But using your method, I would want 0.004" or more of clearance depending on how you are making them.
Your gears will be less efficient and more likely to bind than any COTS gear, not to mention will take far more hours than COTS.