Need Help with Big Sprocket

[RRLedford]

I suggest you consider "segmenting" your sprocket.
Lets say you plan to divide it into six pieces, and you know the saw cuts will allow the segments to collapse inward just enough to get the rollers back down into the roots of the teeth.

You lay out your six slice lines and you mark out three mount holes per segment to be drilled through each segment and through whatever the sprocket mounts to. You drill your mount holes BEFORE you slice up the sprocket into segments.

Now by slightly oversizing the three through holes in each segment, relative to the mounting fastener OD, you can shift the segment locations radially, thus shrinking the effective sprocket diameter enough to maintain decent chain wrap engagement across all the segments throughout the full circle.

I would use shoulder screws for mounting the sprocket segments and an adjustable reamer to gradually increase the sprocket mount holes' size until your chain seats fully into all six of the segment arcs (well, only three at a time really).

-Dick Ledford