You can also purchase for about 8 bucks at my LHS a set of aluminum gear for 40 or 60 size, they are blanks so you can just drill accordingly, then tap the mounting block like Brit's talking about. I think that is the way I'm gonna go. It's less work & they are a wider one piece gear. (wider at the mounting block)
http://h1072469.hobbyshopnow.com/pro...sp?prod=HAN140
These are very similar to the ones I saw at the store. They are apparrently pre-drilled as well. I thouhgt they were blanks, better yet.