[sanddrag]

First off, I know nothing about pressure angle but I will try to answer your other questions.

Personally I would use no gears and only sprockets. They are also easy to find with finished keyway bores. Do your self a favor and don't custom make anything or weld anything. Try to find parts that will just bolt together and you'll save yourself much time and trouble.

If you insist on using gears, I actually haven't seen any stock keyway ones. We would just pin gears and use keyed sprockets. Now we don't even use gears at all and I don't want to ever again. Our experience with 32 pitch gears was to horrific to describe so just trust me and don't use 32 P. However this does present a problem if you are using the Chiaphua motor. There is nothing that will fit on or mate with that shaft other than a 32P gear such as the Bronze alloy Cluster gear supplied in the kit of parts. If the chiaphua will be used, the only good way is with a very custom CNC-ed shaft that fits over the splines on the Chia armature.


BTW - Is this whole project your presenting to us all an attempt to get a jump start on the season? If so, I think it's great. I wish my team could build a gearbox over the summer. Also, what motors will you be using and what are your thoughts on multiple gears/speeds.