Help wanted with sanity check for a 40PA hob cutting tool

[CanBeDone]

Instead of answering your implied questions, I will provide you with a link. From that link I have taken this photo

which shows a simple way to cut gears using a vertical mill. If you follow the link provided by AI8236, you'll end up on a web site that very much has written down what I think on how to design a gear cutter - VERY different from your ideas. If you add to this that you can buy finished gear hobs for under 50 US$ from e.g. aliexpress.com, that is the way I would tackle gear cutting.