Do you have a friend with a lathe and milling machine and some form of indexing? For a rough slow speed application the gear teeth don't have to be perfect. I saw an article about making a similar gear one time. It was done with endmills, tapered endmills, countersink used as endmill, etc. to approximate the tooth shape. I think it was for an old winch or some such non critical application and worked perfectly. It would be an interesting project for someone with the tooling.
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