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Re: Chains
If you recruited a sheet metal sponsor and would like to pursue drive trains like the one you linked to; simply make the outer chassis rail removable. Then you can take the entire outer rail off to access the wheels and chain.
If you are going this route, calculate your chain paths ahead of time and design for an exact number of chain links. Then when it comes time to assemble the drive train, you can simply make all the loops of chain ahead of time and pop them in place as you mount the wheels, sprockets, and any spacers or shaft collars.
For tensioners, you can use floating idlers in the chain runs, or add a lot of standoff mounting options in the drive train. Press a Delrin sleeve over the standoffs and then move the standoffs around as necessary to act as a chain tensioner.
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