Have a look at this novel method of making a wooden gear. The creator used the Gear Template Generator designed by Matthias Wandel to create two gear patterns. After gluing one of the patterns to a circular piece of wood, holes were drilled into the edge at the proper increments. The beads came with a hole through the middle, so all that was done to them was to add a countersink for the screw head. Finally, the beads were screwed to the circle, creating the finished product you see in the image.
Here is where you can see the full project and more details about this woooden gear with beads for teeth.
[ Thanks John! ]