pic: Inverted CIM 2-Speed Gearbox

[KohKohPuffs]

I must bring back this discussion to ask some questions regarding this design, mainly because I'm considering making another inverted CIM gearbox with more desirable high/low speeds.

1a. How can I provide enough space in between the CIMs for the gears without using the original idler design, but not go into belts (This is something I'll consider later on) or custom gears?

1b. So what if I decide to stick with my first first stage design? Because I don't think that anything bad will happen if I do it. For one, the gears are made of steel, and even if it does wear out, the design is made so that those gears are easily replaceable.

2. How can I bring down the weight to a minimum? I came across a topic on CD regarding delrin gearbox plates, and I was thinking about polycarbonate plates beforehand, but I'm not sure if either of those are good ideas.