I'm thinking about a cutter for the pulley teeth. Normally I'd do another fly cutter with a lathe tool as a single point. But I'm worried about my spin collet holding. It's an old 5C type, and I remember that with past gear cutting attempts, that I had problems with it slipping.
The vibration of a single tooth cutter and multiple passes is something I'd like to get away from, if possible. It seems like cutting 90 teeth without a single mistake is a fairly difficult proposition (for me, not you reading this!) , but I'm of course going to rush in anyway.
I'm going to have to keep my wits about me as there is a 36 hole disk, with a ten hole "vernier" to yield 360 parts. This means I will have to cut once, then peg the #4 hole, cut, peg the #8 hole, cut, rotate disk one and peg the #2 hole, cut, then #6 hole, cut, rotate disk one, etc. Also advancing X. If I have a multi tooth cutter, and if I can get away with a single pass, no Y traverses. Otherwise, multiple Y moves, then return. Many chances to ruin the blank.
So that's why I'd like a multi tooth cutter.
I have in mind the way I want to make one, using the lathe to first turn the profile, then milling teeth somewhat like I made the Acme tap, a long time ago in this lathe thread. I just have to research the angles and settings I will need to get there. The depth of tooth and diameter of the tool stock will determine how many teeth I can have -- I'll probably use that 1-1/8" ground stock that Lester sold me as "cold rolled". Beautiful stuff to machine, and I suspect it may be really drill rod and hardenable. If not, I have some real Kasenite as backup.
Too late to noodle it out tonight, but I hope to have a plan tomorrow....