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Originally Posted by SarahB
Plus he said he was possibly using 16 pitch gears, and steel 16 pitch gears are a lot stronger than your average shifter.
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Actually, this really depends on what you mean by "average shifter" I would wholeheartedly rather bet me life savings (which is admittedly negative since I'm a college student) on a dog style shifter than gears engaging face to face, if you're speaking about going on the fly.
WHICH THIS DESIGN IS NOT INTENDED TO HANDLE. 
I've plugged some numbers into a Lewis bending equation spreadsheet I've made, and let me tell you, with the 1" gears, failure is VERY possible, depending on where you place it in the drive train. Using the initial configuration I had, the factor of safety was around 0.7...
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Keep in mind, his design doesn't even use #25 chain.
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I most definitely do use #25 chain in this design, since it's loads are planned to be somewhat light. If I were placing this on a drive train, I'd probably slow the Chips down by maybe by 3 or 4, throw that shaft into this magic box, and probably use sprockets on the wheels to slim it down by another 4. By this, I don't expect the gear box to see torques exceeding around 50 or 75 in-lbs. I think that #25 is safe in these situations, even with the small diameter of the sprockets being used. #35 chain might add another half pound per box, for no real good reason.
Just some thoughts,
Matt