I have repaired alot of gears on old machines that needed dental work. I dont know how big the gear or the tooth is, but, on bigger teeth, I have drilled and popped steel pins into the broken area, then filled up with brazing material.
You have to take your time, both building up then the final fit of the tooth. A trick you can use is once you are pretty much done, cover the new tooth in dykem or machinist blue, install it in the lathe and SLOWLY BY HAND, run it over a bunch of times. Try to "feel" for binding as the new tooth meshes. Take the gear back out and inspect the dyed area. If you have a big high spot somewhere on it, the dykem will wear of quicker there. Then adjust as you see fit.
Good Luck
Phil
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