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Originally Posted by Max Lobovsky
How have teams cut holes in their sprockets and gears to interface with the flat sided shafts of the Globe and sliding door motor? Even with mill, there is no way to cut the edge between the curved and flat parts of the motor. Leave that edge with an oversize fillet? Would a circumscribed rectangle work? Is there any way to do a sloppy job if you can't get to a mill?
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The Machine shop that donated work for our team last year did it with a wire burner. He was able to cut the proper hole for a globe shaft in a 9 tooth #25 stainless sprocket, that started with a 1/4" bore. We had no issues with that sprocket hope to visit him again and get another one or two made for this year.