Thanks for all the responses, I haven't used chains in 4 years and I guess I expected it to be a bit less taunt. We'll be sure to implement some method of tensioning in the next few days now that I understand what's happening.
Quote:
Originally Posted by BBray_T1296
This is what I am guessing is roughly the situation you are describing. If it isn't, I cannot imagine the concept is much different.
The slack is a result of the chain's slight ability to stretch, and in this situation is fairly normal, Unless your chain is very loose, even with no loads at all, in which case you should shorten the chain. In the setup pictured that slack can hardly be helped and has likely little effect on the performance.
Another beautiful drawing courtesy of yours truly 
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Yes, that is very close to our design. The force vectors really helped me understand why one side is slacking, thanks!
Quote:
Originally Posted by Ty Tremblay
This leads me to believe that your 1:1.5 ratio allowed your motor to run closer to it's maximum power.
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I just thought that the difference between 1 and 1.5 wouldn't be so significant, it went from pulling it with ease to barely making it.