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Re: Lightweight belt sprocket
The attached picture shows what we do to 60 tooth Gates sprockets to make them considerably lighter. We use a combination of lathe and mill, but you can do it all with either if you only have one, as long as you have a rotary table for your mill.
Keep in mind also that you only need to use a belt sprocket for the roller that is driving the belt, you can make any other rollers out of PVC pipe or any other lightweight round stock you have access to.
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