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Your best option is to use the Solidworks Toolbox.
ANSI Inch - Power Transmisions - Gears.
You can build Gears and Pinions there.
If I had to do it by hand I would create the blank and use a lofted cut to create the internal tooth profile. I would then use a circular pattern to create the rest of the teeth.
n terms of the calculations you will need a very good gear catalog or Machinery Handbook, to get the calculations required to create the profile.
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