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We know this part number is the one that didn't work out: 35377159. I don't think our team has the capability to machine the steel, so we need something with pre-drilled holes.
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A regular ol' hand drill will get through steel, but you'll need to be very precise with your measurements.
As far as aluminum sprockets go, let me share a little story. Our rookie year (2004) we purchased these humongous steel sprockets thinking we would need them. We used 1/4 aluminum in our base, and made our goal grabber out of steel. We had a very elegant robot until around 3 days til shipdate when we weighed the thing. 143lbs?!!??!? Oh Noes!!! We lost a lot of our ball holding ability to cut the weight down, as well as drill quite a few not-exactly-in-a-line speed holes. We ended up making weight (which was 130 lbs with the battery).
Fast forward 4 years...
A few nights ago we got a package from AM containing our aluminum #25 sprockets for this years drivetrain. While sitting in our room someone pulled out these giant steel #35 sprockets and we couldn't stop laughing thinking about how we thought that we needed that much strength.