It was fascinating to read the patent application, thanks Michael for tracking it down. Unfortunately no clues about using the smaller gear, metric seems to get only one brief mention.
Below is a picture of the stud/sleeve/key arrangement. It might be possible to make a stepped sleeve that would allow the use of a gear with a reduced bore.

Still going to be tight, but worth investigating. Rod has very kindly made a couple of 17t gears, one of which is un-bored so could be adapted for use on a stepped sleeve, so I may now have a potential solution that would retain the originality of the unit.
Brian – Thank you for the offer to recalculate the ratios. I'll try and establish the constraints on gear size for each position to see if this could be an alternative way forward.
Thanks again to all for your inputs.
Philip