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I would just cut out the idea of aluminum or steel sprockets. Because drive gears/sprockets are under constant force and stree during the match, you want to use steel or cast iron. It's heavy, I agree, but it is the best choice. Our team gets sprockets/chains/gears machined by Borg Warner people and realize they make 90% of the world's small car chains and 80% of the larger automobile chains... such schweet quality.
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Code Red Robotics Team 639 Alumnus | www.team639.org
<Patrician|Away> what does your robot do, sam
<bovril> it collects data about the surrounding environment, then discards it and drives into walls
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