Frank,

Well the reason I am looking into using roller chain is to allow it to 
match up with all the standard roller chain sprockets. I would be able to 
get any standard roller chain sprocket, tensioner or other product designed 
for roller chain cheaply and easily. You could use the roller chain 
calculators to determine correct sprocket spacing. Another key reason is 
that roller chain is mass produced which means that those parts are widely 
available and cheap. Up to this design the only custom part was the tread. 
So rather then getting several parts custom made I would only need to get 
one custom made. 

The new horn plate is now a new custom part. But the geometry is fairly 
simple. I would only be a single part mold. If I can use two of those parts 
back to back to create a center horn, then I could use the same mold. 

I am looking at being able to make these in small batches myself, but 
mostly at trying to make them in bulk and sell to hobbyists. I know that 
you guys are focused on tank replicas and I would like the track to match 
those goals. But I am hoping that robotic hobbyists could also benefit from 
this design. So building tanks, tracked robots, RC lawn mowers, bomb 
disposal robots, and hopefully more.

That is a little bit about my thought process that got me to this point. 

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