Folks,

A couple of questions if you don't mind...
Scenario - I'm building some backgears for a Taig lathe (small lathe
the size of a sherline - chuck is nominally 2.5-3" in diameter) and
will be cutting the gears with a silver steel (Drill rod) parallel hob

The bull wheel will be around 3.5" in diameter at most and the mating
spur wheel will be around 1" (up to 1.5")
The face of the wheels will be in the 10-12mm (3/8" - 1/2") range and
the lathe uses a 350W (0.5 hp) motor off a 1/8" gates v-belt

What would be a suitable material for the bull wheel which can be cut
using a homemade cutter?
materials I have available include:
mild steel, aluminium, nylon, brass (if I can get the foundry up
running again)

I'm worried about using the home made cutter on mild steel due to
reading about burning the cutter - or am I worrying for no good
reason?
Aluminium, brass and nylon are easier to cut, but I keep reading that
aluminum should not be used for gears becuase it's deemd high
friction, and would gall...

any tips or suggestions?
any machines out there of similar size with backgears - what are those
gears made of?

Thanks,
Des