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Does anyone know how to make a simple gear that is about the size of a sprocket.... do you use a cutter, saw, melt it down, ???
 

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What are you gonna be using it for? You can buy super cheap cogs from your LBS, well most i would say. Cheap as in $5-10 at most.
 

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Does anyone know how to make a simple gear that is about the size of a sprocket.... do you use a cutter, saw, melt it down, ???
First: I agree with tajcrews, buying a cog is likely your best bet.

With that said- most modern cogs are made on computer controlled milling machines like this:
[ame=http://www.youtube.com/watch?v=TJ_cjq-KYE4]YouTube - Making Gears[/ame]
 
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