@Rocket Scientist
You should see if Patrick @albertaduke has anything left out of his Roaster I cannot remember what he did with the internals but I know he pulled it apart!
Here is a picture of the trans gears from a 1960's Honda 305. I had several of these as a youngin'. Look at the under cut on those gears. Yoo-Hoo Triumph.
nice depiction. I can see how it helps and I can see this done on a tool and cutter grinder or even a surface grinder with a proper fixture. Now the internal spokes of the female gears are what throwing me other then having them done by EDM the only thing I can see doing it would be something like Moore a Jig Grinder.Of course all pictures I have seen so far and really liked reading the APE site does not show female dog spokes just male to male. Maybe when you have that type of gear its only the male dogs that get ground.
I also like the self locking one but I am not sure if you can get into some of them to set the locks. It sucks not have parts laying around to look at. Self-Locking Rings
Oh and that's a nice Classic especially for 4k doesn't match color wise but you change the tins and bags out and you red beast is back..
Of course I understand wanting to fix yours yourself and can only say there can be a differences in the price of what a rocket is worth to the public and to ones self. I know yours and mine are older and we have seen a hand full of new ones lately develop some problems. What I cannot figure out is why are the Touring models not having the same issues.
Fred These are the guys the made the 4 gear out put I would not be afraid to call and ask as at least they had there hands on parts of one if not all. I went thru my emails from 2015 their number 631-630-9219 The guy I was told to ask for is Bill.