Puch 32 Tooth Rear Sprocket

I've been looking for a 32 tooth rear sprocket for over a year now.  I've scoured the forums and asked my friends with no success.  I have two of them, but they're trapped on my bikes currently stored in Hawaii.  So, I decided to make one.  I initially contacted Chris at 1977mopeds to see if they could get or make one for me:



"We actually made a prototype of an 32 rear sprocket, unfortunately they would be cost prohibitive to produce I do not think many people would be willing to pay 60 for a sprocket.  The 30t brings up other issues, the major one is there is not enough room for the bolt heads to clear the chain. You can get away from this by instead of using through holds you drill and tap the sprocket and then screw bolts into it from the back.

If you are willing to spend money to get custom sprockets made you can check with these guys. They do good work as I have used them for personal projects in the past:
http://www.sprocketspecialists.com

Thanks,
Chris"

So I contacted Sprocket Specialist:

"If you supply a sample sprocket we can build you a 415 sprocket. The cost is $69.99 with $15.00 special build fee."

A little steep for my top-end desires.  I decided to research more.  I found a 32 tooth sprocket for a Garelli at Treats for $14.  All I needed was to find somewhere locally that could machine the center to 94mm and drill the holes.  Come to find out, our very own Soma-san has a friend who owns a motorcycle shop and knows a shop to machine it for me.

Here's the result:

36 Tooth (L)   -   32 Tooth uncut (R)

36 Tooth (L)  - 32 Tooth (R)

DIY:  If you don't have access to a machine shop, it is possible to enlarge the center hole yourself.  The motorized bike community came up with some inventive ways on doing this:

Here's some forums posts discussing their methods:

•  Enlarge Sprocket Center? 
•  My rear drive sprocket doesn't fit over my hub. HELP!

The keys for our purposes are:

1. To scribe the new center hole diameter of 94mm onto the new sprocket.
2. To enlarge the hole enough to clear the hub.
3. To drill out the mounting holes in the correct locations. 

I created a template of the center and mounting holes.  Just print out this PDF file and use it as a guide.
(Note:  Be sure print setting in Adobe is "Actual Size".  Verify print scaling via 50mm scale on sheet)

Update:  After further research, I found a couple of places that can make a 32 sprocket out of aluminum:

• Kings Sale And Service

"It would be $42.50 plus $5.00 for shipping in the USA (it would be made of 7075 T651). ....have to pt the 94 mm center hole and no mounting holes in the notes to seller section to remind us."

• Rebel Gears Motorcycle Sprockets USA

"The sprocket is $43.50 the freight is $6.70.  You can Call me with a credit card number when your ready to place your order."

(Note:  These prices are only for the sprocket and center cut.  No mounting holes.  It's was difficult to accurately give them specs for the mounting hole positions.  Just use a sample sprocket and drill them out yourself.  Also, please specify your chain size of 415 for Puch.)