Board Thread:General Nerf discussion/@comment-26431461-20190529022825/@comment-27306930-20190529032512

Preface: I am not a 3D printing expert. Yet.

Cutting the ABS gear shouldn't weaken it. Use a high-tooth saw to preserve as much material as possible. This Xacto Razor Saw is the perfect tool.

But you bring up a good point. It sounds like there's a design flaw involving the forces on the secondary gear (aka tangential force). If you go through all the trouble to make a new gear, is it just going to break again ?

I'd try printing a new gear and see how that works. You already know how the nylon ones work. Print in ABS or Polycarbonate. Use the highest infill density your printer will support.