I have a need for 8 tooth sprockets and worked out a design after examining a few different sized sprockets salvaged from bicycles. After making one from Aluminium I steeped up to 3mm thick steel, which was easier to work with in some ways.
Originally I thought I would have to get something like this CNC cut, but I got pretty good results with basic tools. You could probably lay out the design on the steel with dividers but I find punching printouts easier.
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