I agree, the drive sprocket can not be anything but alloy steel, however if you do it right, you can pull off an aluminum driven sprocket. Our issues in the past I believe to be poor material selection and poor design. 7075 al t6, hard anodized is what we're going for this year

guys i have a query...what do you prefer machining a aluminium (7075-T6 hard anodised) blank sprocket shipped from sprocket specialists(about $55 +shipping to India) ,or, a alloy steel sprocket bought from local market(blank costs about $10 ) +machining the teeth and the webs.There would be a small difference in the weight though.

@ drywater

It would be better to import the sprockets. I am planning to import them soon ,if u are interested them let me know .

@sahil.will you be importing them from sprocket specialist..email me your contact number
blackbrains7@gmail.com

Sprocket are not hard to make at all. Our team has been running a 600 cc engine for the past decade and have manufactured our own driven sprockets every year.

Drawing them up is not difficult at all. I used notes from Gizmology to aid me and it worked great. Hint: draw a single tooth first and save it as a template. Now you can use just change angle size depending on which size sprocket you want, and do a circular pattern to create each new sprocket.

As for galling, we have typically experienced few-to-no problems. We can usually run sprockets for 2-3 years before they break due to overeager freshmen downshifting too early during summer jolly driving.

Just make sure to pick a good alloy of aluminum that you think will work. Which one is up to you, you're the engineer after all.