First off I want to thank everyone for the help in the design so far. The 
feedback has been great and being able to get answers to some questions has 
really pushed my design forward. I have done some redesign and was curious 
about peoples thoughts. I looked through the various links and that gave me 
some inspiration. So this new design is still similar and still uses 
standard roller chain. There is a tread that is molded over two pins. These 
pins replace the pins that are pressed into roller chain. I have talked 
with a roller chain manufacturer and they said they would be willing to 
sell me assembled chain parts if I got them in large enough quantities. 

I also designed a replacement roller chain plate that has the horn feature 
built into it. What I really like about this is it becomes an option. If 
you want horns you put the horned plate on, if you dont you use a standard 
roller chain plate. That also lets me make changes to the horned plate 
without scrapping the whole design. I had a few questions about the horns. 
These links are 3" wide, about how tall should the horn protrude? What 
width between the horns would be best? and what angle should the horn have 
to push the boogie back in place. Anyone have thoughts on those questions.

I was also planning on using a threaded rod and nylock nuts to hold the 
chain on. This would work okay, but finding a standard bolt that matches 
the roller chain is tough. For #35 a 6-32 fits really well. But other sizes 
don't fit as well. So I got the idea from FOA to use a headless pin and 
snap rings. But when you start looking at snap rings the common sizes dont 
match up very well. I have a few quotes out to snap ring manufactures to 
see if they have an of the shelf size that matches better then what I can 
find quickly. But then it hit me. Master Links for chain have this snap 
ring already and it is designed to hold chain together. So I am gonna call 
my roller chain person tomorrow and talk with him about being able to buy 
only the snap ring part of the master links. If they will sell me the chain 
unassembled, I don't see why they would not sell me the snap ring too. 

I am going to 3d print some of the horned link plates tomorrow at work and 
put them on my models just for testing. I will post photos then. Attached 
are some pictures from the CAD package, a few quick renderings and a short 
video of the assembly process.

<https://lh5.googleusercontent.com/-w3pFLbgK18s/VNmfAHCfOHI/AAAAAAAABZU/HeiNltTpk7w/s1600/Track2.JPG>
 
<https://lh5.googleusercontent.com/-g5gCeHeKrqs/VNmfDwIk78I/AAAAAAAABZc/I5tPp9_UisY/s1600/Track_Rendered.JPG>
 
<https://lh5.googleusercontent.com/-YbD5kAXOdYk/VNmfFnvN_EI/AAAAAAAABZk/1cflo4EBWIo/s1600/Track_Rendered%2Bexpoded.JPG>
 
<https://lh3.googleusercontent.com/-MVZzZjY-mzU/VNmfMFJRd-I/AAAAAAAABZs/KrMSSfM0l5U/s1600/Link2.avi>
 
<https://lh4.googleusercontent.com/-KaxXTtJhxzs/VNme5mj09LI/AAAAAAAABZM/ckR-ip0UMgE/s1600/Track.JPG>

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