Here's my stupid question of the day...can't you replace the plastic gear with a metal one? You could probably find a match in a McMaster-Carr or Grainger catalog and find a local guy to cut a hole and keyway. No worries of breaking then.
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-Steve
"Oar Chasm!"
1977 Wellcraft V20 Step OB cuddy. 1971 1350 Merc
"Any damn fool can navigate the world sober. It takes a really good sailor to do it drunk."
- Sir Francis Chichester
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