Want to Fab Steel Idles Gears Need Some Design Help

[xr650ryder]

Wanting to fab steel idler gears need some design help!:eyebrows:

Please evaluate the following:

The Plan

Use a 6203-2RS bearing. (same as stock Idler)

And one of the Following:

- Bore out an XR650R sprocket to press fit which has an extra boss for thickness that would help support and capture the bearing. Laser tack the bearing in place.

- Fabricate a gear complete to match the Nylon stock gear minus one lip. Laser tack the Bearing in place.
Material 420 Stainless or Roy-alloy leave un-heat treated.


Need some input to the Following Questions:

For the Snow-bikes that have really tight chain between bike and kit and/or TSS wouldn't a 14 tooth Idler be a good option for clearance?

If made from scratch maybe a 13 Tooth?

Is a steel idler the direction we should be going?
( Or guides, slides and tensioners. )

Just use Stock Idler and carry spares?

 

[Rbott]

This is already being done.....

http://www.snowest.com/forum/showthread.php?p=3889806#post3889806

 

[xr650ryder]

Thanx that tread has helped but what do we really want?

This is already being done.....

http://www.snowest.com/forum/showthread.php?p=3889806#post3889806

Thanx, that tread has helped and got me started thinking steel may be the answer to the extra stress the TSS puts on the drive system.
I mostly looking to do R&D not planning on going into production. The 14 Tooth or even 13 makes so much more sense to me. IMO The current Idler is a 15 tooth partially due to material choice.
What do we really want to keep the chain from Flapping?. :juggle:

This first chain is a balancing act of gearing and clearances.

 

[xr650ryder]

What's your thoughts on a 13 tooth idler for bike chain.

I started with the biggest size difference to see if it works.
What's your thoughts on a 13 tooth idler for bike chain tensioner.

Made from a XR650R sprocket and SKF 6203-2RS bearing.
Light press fit and laser tack welded.

The sprocket was dialed-in and cut on a mill.
The bearing has a lip in sprocket to be pressed up against.