Thank you all for waiting on me to get this right. I know I will get this down in the end. I have been able to make the molds correctly and as Buckshot77 said, the parts look right but I have to adjust a little for strength. I did something a little different when i post cured the first gear that I thought would help. Obviously it didn't. I am going to send out a new one today, cured a little different. Then I am looking into adding a filler to the material that should give it more than enough strength to hand this job. All the previous gears I have made are really under little stress. This is a good learning experience for me.
I love a good challange. Thanks for letting me do this one. You will be happy in the end.
Jeff Caplan
http://www.odometergears.com 
