Making Your Own Chain Sprockets, The Tidy Way

Chain sprockets are a key drivetrain component in a lot of builds. Unfortunately they can be difficult to source, particularly for those outside the reach of retailers like McMaster-Carr. In such situations, you might consider making your own.

The toothed profile on a chain sprocket can be produced in a simple manner by drawing a base circle, along with a series of circles spaced appropriately for the chain in question. This involves measuring the pitch and roller diameter of the chain. With these measurements in hand, a template can be created to produce the sprocket.

From there a series of holes are drilled to rough out the basic shape of the teeth, before the sprocket is then cut down to its appropriate outer diameter. The finishing work consists of chamfering the sprocket’s thickness, as well as the filing the sharp edges of the teeth for smooth engagement.

It’s a quick and easy method for producing sprockets with well-defined, accurate profiles. We’ve featured other rough and ready methods before, too. Video after the break.

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How To Make An Electric Scooter Chain Sprocket With Nothing But Hand Tools

Sometimes, mechanical parts can be supremely expensive, or totally unavailable. In those cases, there’s just one option — make it yourself. It was this very situation in which I found myself. My electric scooter had been ever so slightly bested by a faster competitor, and I needed redemption. A gearing change would do the trick, but alas, the chain sprocket I needed simply did not exist from the usual online classifieds.

Thus, I grabbed the only tools I had, busied myself with my task. This is a build that should be replicable by anyone comfortable using a printer, power drill, and rotary tool. Let’s get to work!

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