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For anyone whom doesn't own it as a professional machinist the book Machine Shop Trade Secrets was probably the best $36 you can spend on learning not only how, but when and why to locate something a certain way as well as techniques not commonly available in online info.

It is still a common practice for gears cut on older style , not to mention worn out, gear cutting machines such as sykes, sunderland, etc. That in their hayday could only cut an agma 6 quality gear to "lap in" a set of gears by using a gearbox with abrasive in the lube system to make a matched...

I've used TPG style inserts with an adjustable top mounted chip breaker in small lathes with great sucess. We had a Dorian quick change tool post on an 9x24 that came with a set of holders that held that insert. It held one on each end of the holder, one set up for turning and the other for...

Also if you wanted to maximize cutter life between sharpenings or decided to make the of a tougher material you could rough them in with a ballnose endmill.

Are you using a od specific involute cutter and single index cutting or flat side npa cutter and multistep profile milling? I'm guessing single indexing (multi pass to reach depth) with an involute cutter. If you need any advise on gear cutting let me know, I ran gear cutters and grinders for 15...

That's a nodular iron block with stainless core plugs. We cut cylinder heads with our saw regularly cutting the core plugs and injector and glow plug tubes also.