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Hello Dave,Yes, we all walk the same paths. Good looking gears.Actually the profile of the cutter is probably a second order issue. You can get far bigger and measurable errors if you are a thou or two out when setting the cutter centre height or the outside diameter or PCD. I could probably be in trouble with those fractional inch sizes.One of the biggest sources of error can be getting lost with the vernier wheel on a dividing head. Then you get to ask yourself "How do you want that last tooth to look? One extra wide tooth or two very thin teeth?"I'm now looking for a small slitting saw to gash the steel wheels before the involute cutter. Or I could make and use an undersize cutter, that has the advantage of maintaining centre height with the same tool holder.Mike
The gashing could be done with a small endmill at Y0.
50mm x 0.5mm any good to you?