diarmaid, There are many keyless connectors and clamping sleeves commercially available. Spieth & Ringfeder are both from Germany, Fenner drives in the USA. These make a more secure and stronger coupling than key/keyway fit. As for gear mfg., if you can specify commercially available gears you will save time & money. Otherwise if you prefer to diy, obtain the appropriate single tooth cutter and the gear can be cut on a mill with a dividing head. or a wire EDM. or a gear shaper. or a gear hobber.
Good Luck
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