Originally Posted by
MyRedTrek
Why wouldn't it be possible to re-shape the load-bearing side of the cogs so they'll grab the chain again? I'm envisioning some kind of jig with a round abrasive stone on the order of a Dremel tool to keep the cutting uniform something on the order of an electric chainsaw chain-sharpening tool.
Is the answer "yes you could but it's a ridiculous amount of work for a fairly inexpensive to replace part" or "no it won't work because....." ?
You'd need to remove more than you might think to get the correct roller engagement, there wouldn't be much tooth left. You might think you could recut larger sprockets for a lower tooth count, but mostly the cutouts would be in the way. These things (except for the single piece milled from solid creations) are mostly manufactured by stamping, with little to no other machining involved, the effort to re-engineer them is simply not worth it. Find a cool way to repurpose them, into wall art or lamps or wind chimes or ... just recycle them.