[R.C.]

Originally Posted by artdutra04

They were milled on a CNC machine; you can't laser cut polycarbonate.

As for design decisions, we just made a bunch of different sizes. To tension the chain, simply pop the floating idler sprocket out and move it closer toward one of the driving/driven sprockets. You may have to readjust the idler position somewhat frequently as the chain breaks in, but once the chain finishes stretching you can leave the floating sprockets in the same position for the rest of the season.

If you don't have [access to] a CNC machine, you can always just get plastic (nylon) sprockets and use them as floating idlers.

Art,

Did you guys put a chamfer on the sprockets and how thick are they?

Thanks,

-RC