My Dad has a Royal blower. All the gears are metal and look fine, except for one pressed fiber gear that has all the teech woren off. Is there a source who makes replacement gears, either metal or fiber? He is ready to start blacksmithing like his Dad but just needs the blower up and running.
Thanks for your advice.

Is it possible to use the worn gear as a template for filing a replacement gear from metal or other suitable material?

You might check with your local waterjet company. I think there's software available for straight cut gear teeth, aluminum or brass might be a good choice.

If it's a Royal Western Chief made by Canedy Otto. The part may be found by checking out generic off the shelf gears. I have talked to several smiths who have found gears for them that way.
Finnr