Tim and John, many thanks for your kind offers. I've just had an email back from HPC, they want to quote to make a complete new set, I might as well have a laugh ;-) If their quote isn't silly money then it'll probably be the best option, if not I'll let you know and we can take things from there. Time wise, there isn't a huge hurry, I've still got to get the knee/table assembly in to my workshop and mounted back up on to the column. The motor is at the local rewind shop being converted to delta and having a general spruce up so I can run from a cheapo inverter
Marvin, I downloaded your program, it possibly works, but when I hit enter after putting in the value for DP the app quits so I don't get to see the results. Win XP SP2 (plus whatever useless updates MS has forced upon me!) Using the figures you gave though and my rather dodgy digital caliper they seem to match up pretty well with my gears, so it seems like you're on to a winner there.
Cheers, Rob