Step 6: Cutting The Gears
I drill all the holes first. It's easier to handle a full size board with the drill press than trying to clamp a gear blank that's only 1.5 inches in diameter without splitting it. Also, if something goes wrong, you haven't wasted all that time cutting it out just to have the board split.
After drilling the holes, I cut the gears out around the outside diameter, then I start cutting the teeth.