Hi John,
I have made worm wheels by free hobbing, using acutter made from silver steel just slightly bigger than the worm. Just minimal relief applied with a file.
The work well, but two caveats – gash the blank first to ensure you get the correct number of teeth (I have a 61-tooth gear as a reminder). Secondly, get some engraving brass – the first, expensive sheet of 1/4″ brass I bought produced awful results but the engraving brass worked perfect first time.
I have made plenty of gear wheels using the resulting worm wheels and all have been OK, so I’m happy with the result.
Neil