filing the tooth slots are done in stages, sawing slits opening up the 1/16th holes, then using a flat needle file to enlarge the slots, and finishing...
this instructable is for the steampunkers out there needing brass gears for projects, not acurate or functioning, purely decorative. My next gear project I will spend more time with the dremel tool instead of files and hopefully fab up a working gear set, using thiner brass stock.
Step 1: Find suitable image
google search gear images, found adding "silhouette" to my search found more stensil worthy images.