I did the big gear a little thinner. It is still much wider then the original "straight" gear, so this is absolutely not fragile.
I don't know what you don't like about this gear, it was much praised... If you have real criticisms and specialy constructive ones, you are wellcome and I will improve the design.
BTW, there was an error in the first comment. The fast-release screw was never 3mm, but it is opcionaly 4mm. and that for non-brazilians only.