Quote:
Originally Posted by scottandme
The tentative CAD design for now has us running a 6WD Franken-WCD with the two 15mm belts running inside a 2"x2"x0.125" tube. Not really ideal from a maintenance standpoint, but I'm hoping the belts will reliable enough.
I'm also fond of the divisible by 3 trick, but I think the 18T is the minimum Gates recommends for the 5mm profile, and bigger pulleys have higher load capacity. The 20T is about the biggest pulley size that fits comfortably inside the side rail tube, accounting for the center drop. The next pulley divisible by 3 is the 24T, which is too big. Setting up the 4-jaw isn't too big of a hassle, but I would probably just make a fixture plate for 8 pulleys, probe the existing bores and have the mill drill the bores to 0.5" before broaching them.
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You get a little more freedom if you aren't set on running the belts internal. That would let you pick a lighter profile tubing for your frame as well.