max, Timing belt sprockets are commercially produced either by the gear hobbing or shaping process. Some are castings. To DIY your fly cutter method is probably the most appropriate. However, you must be very accurate as to tooth form. If not, you might have severe belt wear and/or noise. The belts have different shaped teeth between manufacturers and individual designs of each manufacturer, mostly propietary designs. Also, like gears, the form changes slightly with the number of teeth of a given pitch on the sprocket. You will probably end up with a library of cutters. Guard them with your life. lol !!!!
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