[GTJIM]

"Everything takes longer to make and costs more."

The small size of the gear leads people to grossly underestimate the amount of work and time required to make one.

First, it is quite difficult to get the correct specifications from a worn or broken part - the helix angle and tooth profile of the gear has to be correct for it to work properly ... it takes the correct gear cutter and very specialist tooling to cut such a gear - even when the specs are known.

Say 4 hours to set up and cut the gear ... at a gear cutter's charge-out rate of $100 an hour - that is $400 just to get the gear cut ...

Probably well worth trying Anthont Drosos (sp?) - the Opel Parts Guy from Greece - to see it he has any NOS ones!

I could see a one-off unit costing between $800 - $1,000 to get it custom made - and that is providing a gear cutter could be found to do the job in the first place!