[EricH]

Originally Posted by Ironstorm

The outside edge is maybe 2 inches on either side from the perimeter. It is powered by a window motor so I seriously doubt speed will be an issue with the huge gear ratio.

As for sharpness I think it would be pretty hard to cut anything on the edge but it certainly could give you a nasty poke. I figure we could sandwich it with pieces of plastic. Thanks for the opinions.

Sandwiching with plastic would certainly be a good idea, with extra near pinch points like the drive motor. Also add some extra near the sides; it's not uncommon for a robot to tip that far, depending on how high this gear is.