Hi Brian,

> I was thinking to do a loft or sweep, between two copies of the gear profile. Rotate one of them first,
> to sort of match the helicalness...

Yeah if you do a google image search just for "worm gear", a lot of the images that show up do show the flat gear to have some kind of twist to it. That could be done by Loft like you mention, or also by applying a Twist deformation onto an extrusion.

But I think that you won't want to be trying to bend a second worm thread to make that piece.

Probably if the main worm thread is a bit thicker at its tips it would require some more rotational allowance in the other gear, if it's thin enough maybe a totally flat one will work ok I guess.

- Michael