I haven't found a good way to cut my gear teeth with a router.
Dunno if I do it a 'good' way, but works for me. Almost everything I do, the first thing I do is make a really nice master - that way I can rout nice copies. Never done gears, but other projects just as complex. Way I would do them, is make a 'perfect' master. This could mean just one gear tooth, and likely would, I'm not that good. I'd cut a round circle, tack my master down, and rout the one tooth. Then I'd loosen the nails, carefully line the master for the next tooth, tack down, rout, and repeat until all the teeth are done. A bit time consuming, and a bit of a PITA to do, but you get teeth that are all the same. And if I planned on making more, I'd glue the finished gear down, then using the finished gear, rout it out, so I'd wind up with a 1" thick master (I use 1/2" plywood), then I could turn out as many identical duplicates as I wanted. Of course, if you wanted a different size gear, you'd have to go thru the whole drill again. I always scrollsaw something like that out just a hair large, then sand it to the final shape. It all works very well for me, not sure how it will do for someone else - I do tend to do somethings different from other people, but on the otherhand, I am the only one that needs to be happy with the finished product.
"It ain't what you're told, it's what you know." - Granny Weatherwax
Fawkahwe tribal police SWAT Team
Some days, the supply of available curse words is insufficient to meet my demands.
.....Call me a craftsman, artisan, or artistic, and I will accept that. Call me an artist and you will likely get a quite rude comment in return. I am not a @#$%ing artist.