Jason….when I replaced the sacrificial gear last time wear was even across the width of the gear but the teeth had been savaged. I had a crash sometime last year when an operation went wrong because of a badly secured workpiece ( should have taken more notice of the advice in your book). As already said the plastic gear was mutilated so I replaced that with the overoptimistic hope that all would be well. Not so, obviously, although this morning it was a bit quieter. Weather? or perhaps my tinnitus is a bit louder. I know what you mean about the uneven wear pattern on the plastic gear though. My mill had that from brand new but Warco put it right pdq. Have you stripped out the gears on yours?
Mick