Spinner sounds good, I'm ready to pay whatever he asks (well, within reason...my reason, of course).
I rough-cut the bottom block and cowl block; then couldn't stand it any more--went to work on the alum. gear. Here's the result:
First 3 pics, fabbed gear. Frank, I used your numbers but changed the pattern slightly, to leave the front edge straight and put all the taper in the back edge.
Next 2 pics: Couldn't wait to see how it would install/look.
Last pic: Note how, serendipitiousally (??), the angle on the back edge nearly matches the angle of former #2!
This gear is gonna work fine, I'm very happy with it. Fabricated easily; I bent it by C-clamping it onto my table edge and bending by hand, with just a little light tapping with a hammer. 3/4" long 2-56 bolts, 1 3/4" wheels, nylon lock nuts for keepers. Thanks, Frank, for tips and dimensions.
--Ray