Hello Brian.
A very interesting thread. I have long been fascinated with gear pumps, and it's been one of those projects I planned to have a go at one day.
So this may spur me on to finally have a go, just as your bicycle dynamo project did.
I wonder, can you feel even the slightest pressure if you put your finger over the oil pipe outlet while the pump is running?
I have hoped to make one that does produce some pressure, as I plan to use it in an I.C. engine. They do require close clearances all round and are certainly trickier to make successfully than a plunger pump is.
I remember I once bought a new oil pump for a 1975 Triumph Trident motorcycle I was rebuilding. This was a double gear pump with scavenge and feed pump gears. It was a new non genuine pump, so I bench tested it first. It was totally useless, being unable to develop any pressure at all, the internal clearances were just too big.
I stripped, cleaned and carefully reassembled the old original genuine Triumph pump, and when bench tested this was light years better than the rubbish new one. When refitted to the engine it produced 92 PSI at idle.
I am actually working on the refurbishment of a full size gear pump at the moment for a friend. This is from a 1940's A.E.C. double decker bus he is restoring. It is powered by a straight six diesel engine. I have noticed that the edges of the teeth on one side of one of the gears have a slight bevel. The edges should be sharp, so that's one area where pressure will be lost.
Anyway, I am off to find suitable materials for my own gear pump.