Thanks - am starting to look at other methods to machine these - bought a small lathe - might be able to take the gears down to a certain size and then mill the teeth. The semi circle gears however need a lot of work and need a few changes made to the tooling during a cut. I dont want to move the part once it gets machined - I struggle to get them back to where they were with the correct precision - perhaps I need to look at that again, biggest issue I have is stock holding and placement - main issue anyways.