Chris, IIRC that was more or less how the first chain tracks were made.  I 
refer to the article:
http://www.rctankcombat.com/articles/track-systems/

The original fix to the derailing was to skip the sprockets and go to a 
friction drive.  I'm going to make larger sprockets that will engage the 
track itself, not the chain.  I'm thinking plywood might be enough, 
definitely test some of that before plunging in to cut aluminum though, 
even if I need metal in the end.

Jean, if you only got an eighth of an inch between tracks, it's never gonna 
work right.  Looking at the M1 Abrams(my build), the tracks are designed so 
the lugs on the outside the sprockets engage have space between them 
roughly the same as the length of the lug.  This gives enough space for a 
decent sprocket tooth to engage the track.  I'm not doing it quite like 
that, so the gaps are thinner, but you do have to make them big enough for 
a decent sprocket tooth.  The Abrams has about 11 teeth on the track 
sprockets, even scaled down, that means a lot more than 1/8" between track 
pads.  Gotta have the space to make it work.

I've messed around with this a bit in Solidworks, and I'll mess around some 
more most likely before I start making stuff, and do some simple tests 
before going whole hog.

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