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Re: how to design sprockets
I'm just curious why it is you need to machine your own sprockets. As it was said above, sprockets are so innexpensive, that I can not see the need to spend the time making them in the shop. (other than to say that you made the sprockets yourself - Something I might do - even though it is impractical). 
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"Jack of all trades, master of none, though offtimes better than master of one".
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