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We are in the process of scrounging a
large enough piece of 6061 T6 to make a 127-tooth gear to allow
metric threading.
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What size are you looking for? I have some hunks, free if you want them.
Thanks for your kind offer. We received a donation of two
aluminium 6061 T6 "logs" from some local firms that do aircraft
work. one 6 inches in diameter and one 3 inches in diameter. I
think we can slice this up like a salami for the gear blanks.

Has anyone used the Fortal aluminum alloy showing up on
http://www.mousebar.com/fhome.html ? Claim is that it as strong
(or stronger) than 1020 steel. Prices look good. Any down sides
or tricks to machining?

GmcD