Great descriptions... we have both a wire & plunge EDM at the UofU (I will grab some pics). The wire will cut anything on a ruled surface, including tapered splines (such as a pitman), really cool technology. The U is also working on a EDM design of their own using a substantial grant, pretty...
Email me with some specs, I may have some solutions for you... We (the U if U) have quite a bit of gear cutting stuff (EDM, etc). We are currently working on a set of helical gears for our Mini-Baja car... :D
EDIT: looks like you already got it taken care of... looks sweet! The offer still...