Re: how to design sprockets
 

RAGE cnc'd us some sprockets out of delrin for testing purposes in our drive train... which reminds me we should test them lol. Compared to steel, these things were as light as air and seemed to be pretty strong. I'm not sure if it will hold up through the bashings of our transmission though ;)

sprocket "blanks"
 

Since we don't have access to a milling machine, I've been trying to find a source of reasonably priced aluminum sprockets. This may be a good source

http://www.jackssmallengines.com/gok...msprkt_35f.cfm

19 to 94 teeth, prices from $14 to $36. Looks like they will custom drill them, though they don't list the cost for that.

Now all I need is a reasonably light flange with a keyway to attach them to a 1/2" or 5/8" shaft.