Just met with my machinist.
The gear is a little complicated with a gear on the outside and a gear on the inside.
He estimates the gear will be in the $80 - $90 range. It will be made out of billet steel.
I have a set of pedals that I'll try the gear on.
I will offer the gear separately as well as a repair and exchange program... you send me your pedal assembly, I repair it and send it back or you send me money and I send you a repaired pedal assembly, when I get your pedal assembly back I refund the core charge.
Of course I'll have detailed instructions for installation and R&R.