Hi David,
Not much to add compared with these other chaps.
However, back in the 70’s and knowing nothing about clock building, I ground a fly cutter in silver steel, hardened and ground it.
As you can determine from the poorly formed root radius (radii), the cutter didn’t have a full-form profile.
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Instead, I approached the locking and clearance faces of the wheel from different angles.
For reference, the wheel was made from silver steel too, hardened/tempered, and the locking faces lapped. The fifteen tooth wheel has an OD of ¾” (19mm) and is 1/16” (1.5mm) thick.
Good luck.
Sam
Edited By Sam Stones on 10/05/2016 21:44:33