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Paul B’s DIY track design uses two bicycle chains reconstructed side by side, plastic-conduit tread pieces, and a sprocket that engages one chain while the tread attaches to the other. That layout addresses a common snag in home-built tracks: fasteners can block sprocket teeth, forcing builders to rely on a friction wheel that may slip. The concept offers positive chain drive, but the 2015 project coverage does not establish a payload, torque rating, or measured traction result.
How the double-wide track solves a drive problem
In a simple chain-track layout, tread blocks can be fastened through a single chain. Those fasteners may obstruct the sprocket teeth, so some designs push a smooth wheel against the inside of the track instead. That is friction drive: torque depends partly on the wheel maintaining enough pressure and grip against the track.
Paul B’s arrangement separates the jobs. The tread pieces attach along one chain side, while a sprocket engages the unobstructed chain on the other. Interlocking sprocket and chain geometry transmits torque without relying only on a smooth wheel pressing against the track. Hackaday described the design in a May 6, 2015 feature by Ethan Zonca; the builder’s construction notes are in a RobotShop community post.
Read the Hackaday feature · Read Paul B’s build discussion
#1 Best Overall
- Package Includes: The kit includes 1 set 6/7/8 speed chain, 1pcs bike link plier with hook, 1pcs chain breaker and 3 pairs of bicycle chain buckle, they are efficient, accurate matching and labor-saving.
- High-quality Material: Our bike chains are made of special forging steel which is repeated forged and strict controlled of materials to ensure the strength. The are full plating silver to anti-rust, high cost performance, anti-corrosion, wear-resistant and durable.
- Double X Bridge Design: Double X bridge design of the bike chain kit improves the tensile, torsional strength of the chain and have variable speed fluency improvement.
- Easy to Install: The bike chain is easy to install, you can determine the length of your chain according to the original chain, cut out the length you want with a chain cutter, and install the chain with a chain hook.
- Wide Application: The bike chain kit is suitable for 6-speed, 7-speed, 8-speed road and mountain bikes. It is suitable for shimano and SRAM variable-speed systems.
What the documented build uses
- Two BMX-style bicycle chains, broken down and rebuilt as a double-wide assembly.
- M3 machine screws in place of the original chain pins, with nylon-insert nuts.
- Plastic conduit cut into tread sections.
- A chain delinker or breaker tool and a sprocket that matches the chain being used.
- For a complete vehicle: support rollers or wheels, a frame, axle, bearings, and a motor and gearbox sized for the load.
Paul B said he had considered automotive timing chain but chose bicycle chain for a smaller-scale prototype because timing chain and sprockets were expensive. He also noted that M3.5 screws might have fit better, but were harder to source in quantity. These are choices reported for that prototype, not a general load rating or a current parts recommendation.
How the chain assembly works
- Break down two bicycle chains completely with a chain tool.
- Align the chains side by side so their links remain parallel.
- Reassemble them with M3 screws in place of the connecting pins and secure them with nylon-insert nuts.
- Leave each joint free to pivot. Tightening nuts firmly against the plates can bind the links and prevent the track from bending around its sprocket or idler.
- Attach conduit tread sections to the outer chain side, then position the drive sprocket to engage the other side.
This is a description of the mechanism, not a dimensioned fabrication plan. The cited accounts do not specify chain length, conduit diameter or wall thickness, tread spacing, sprocket tooth count, axle dimensions, or a complete bill of materials.
Rank #2
- REPLACEMENT CHAIN: Fix up and replace worn and damaged chains with a replacement 1/2" x 1/8" Schwinn Bike Chain. Made to work with a variety of non-derailleur bikes, including BMX, cruisers and more.
- SMOOTHER RIDING: Replacement chain fits most adult single speed bikes, keeping your ride smooth and effective on mountain trails and road rides alike.
- HEAVY DUTY CHAIN: This 1/2" x 1/8" chain features 112 links and a heavy-duty build for lasting strength. An anti-drop design keeps your ride smooth, secure, and ready for the long haul.
- EASY REPLACEMENT: Designed for simple replacement, this chain works with the Schwinn Chain Tool and other tools for DIY repairs.
- TRUSTED SCHWINN QUALITY: Schwinn is the original American bike brand. We’ve spent over 130 years building the bicycle industry into what it is today, and we’re not done yet. Each product is designed in Madison, WI.
Traction is not the same as positive drive
The sprocket-and-chain interface can reduce slip between the drivetrain and track. It does not, by itself, guarantee grip between the tread and the ground. Terrain traction depends on tread shape and material, vehicle weight, contact area, surface conditions, and whether the soil or snow shears beneath the track.
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The conduit’s exact polymer, surface texture, and wear performance are not specified in the coverage. Cut conduit is inexpensive and easy to work with, but a smooth section may grip less well than rubber, polyurethane, or a cleated tread. Nor does the feature report tests on mud, snow, rock, or pavement. The design’s central mechanical idea is its sprocket engagement, not a demonstrated advantage for every surface.
Rank #3
- 【6/7/8 Speed Chain】- Package includes 1 set 6/7/8 speed bike chain, whose size is 1/2×3/32 inch, the bike chain has 116 links, you can adjust length according to the length of your bike chain.
- 【Double X Bridge Design】- Our bike chain adopts double X bridge design, which improves the tensile, torsional strength of the chain and variable speed fluency.
- 【Special Forging Steel】- 6/7/8 speed bike chain is made of special forging steel which is repeated forged and strict controlled of materials to ensure the strength. Full plating sliver is anti-rust, anti-corrosion, wear-resistant, high cost performance and durable for use.
- 【Easy to Install】- The bike chain is easy to install, you can determine the length of your chain according to the original chain, cut out the length you want with a chain cutter, and install the chain with a chain hook. NOTE: chain cutter and hook is not included.
- 【Wide Application】- Bike chain is suitable for 6/7/8 speed mountain bike chain, road bike and other bikes, and it is suitable for foldable bikes, BMX, etc.
Choosing chain and tread for a real vehicle
Bicycle chain
Bicycle chain is accessible, articulated, and can be cut to length with familiar tools. If paired with a sprocket of matching pitch, it provides a direct mechanical drive. But bicycle chain is not automatically suitable for a heavy robot: pins, rollers, and side plates can face shock loads, wear, side play, and uneven loading. The paired chains also need to stay aligned and share load.
Other track approaches
Industrial roller chain can offer standardized pitches and a broader basis for engineered sprocket selection, at the cost of added weight and expense. Purpose-built attachment chain can simplify tread mounting. Rubber or polyurethane tracks can improve conformity and reduce noise or vibration, but introduce compatibility, sourcing, and replacement considerations. Wheels are often more efficient and easier to steer where terrain does not demand tracks. The right choice depends on load, terrain, speed, service life, and fabrication capability—not the word “traction” in a project title.
Rank #4
- Easy to install: chain joints for the magic buckle, easy to disassemble, easy to clean, reusable
- Strong Rally: Special forging steel, repeated forging, strict control of materials to ensure the strength
- Smooth lubrication: surface polishing, internal oiling
- Accurate matching: professional equipment test spacing, professional and technical test data
- Durable: rust and corrosion
Designing the rest of the drivetrain
A track is only one part of the drive system. Select the motor, reduction, sprocket, shaft, bearings, and frame as a connected load path. Positive engagement prevents the drive wheel from depending solely on friction, but it also sends shock loads directly through the chain, M3 fasteners, tread attachments, shaft, and supports. A weak part elsewhere can still fail first.
Tracked steering matters too. Many two-track robots turn by varying or reversing the left and right track speeds. Pivoting on a high-grip surface can take substantially more effort than rolling straight, stressing motors, shafts, and the frame. Independent drive or a suitable differential arrangement is needed; the track hardware alone is not a complete vehicle-control system.
Best Value
- Complete Kit: Includes 6/7/8 speed chain, link plier, chain breaker with hook and spare pin, 6 pairs of bicycle chain buckle and user manual for efficient and accurate matching, making bike maintenance labor-saving.
- High-Quality Material: Made of special forging steel with full plating silver to resist rust, corrosion, and wear, ensuring strength and durability for long-lasting performance.
- Easy Installation: The bike chain is easy to install and suitable for 6-speed, 7-speed, 8-speed road, and mountain bikes, compatible with shimano and SRAM variable-speed systems.
- Convenient Link Pliers: Bike link pliers allow quick and easy removal and joining of chain links with anti-slip handles for a firm grip and more control.
- Easy Break & Rechain: The bike chain splitter with a chain hook makes it easier and faster to remove and insert pins in your bike chain, compatible with 6, 7, 8, 9, 10, 11, and single-speed bicycle chains.
Tension, alignment, and commissioning
General track-design practice favors an adjustable idler or sliding bearing block rather than a fixed, highly tensioned loop. Too much tension increases friction and loads on the chain, bearings, and shafts; too little can let the track derail, climb sprocket teeth, or strike the chassis. Set alignment so the sprocket, idler, and support rollers run parallel, and provide enough support to limit sagging spans.
- With power disconnected, rotate the track by hand and check that every joint articulates freely.
- Check sprocket engagement, track alignment, and clearance from the chassis.
- Run each track unloaded at low speed, then check forward and reverse travel.
- Test turning gradually, beginning with low-load turns before pivoting on high-grip ground.
- Inspect for loose fasteners, binding, derailment, cracking around conduit holes, and signs of unequal chain loading.
- Increase load gradually and retest on controlled surfaces before operating over rough terrain.
These are commissioning recommendations, not tests documented for Paul B’s machine. Exposed chains and sprockets also create pinch points: guard them against contact with people, clothing, wiring, and debris.
What the project does—and does not—prove
The 2015 feature and the builder’s forum post establish the basic architecture: BMX-style chain rebuilt double-wide with M3 screws, conduit tread, and a sprocket engaging the chain side left clear of the tread attachments. The builder’s stated ambition included making a machine capable of pulling a car through snow, but the detailed post describes a smaller-scale prototype and does not verify that performance.
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Fix the driver behind crashes, sound loss and screen glitchesFind Drivers →Clear out junk files and repair common Windows errorsFree Scan →Scan for outdated or missing drivers - takes under a minuteDriver Scan →The available accounts provide no quantified drawbar pull, payload, motor torque, speed, track tension, service life, or controlled surface testing. The feature’s suggestion that the design can transmit as much torque as the drivetrain produces is a design rationale, not a measured capacity. The chain, fasteners, tread attachments, sprocket, bearings, and frame each impose limits.
Quick Recap
When this DIY approach makes sense
- Consider it for an experimental small or medium robot when accessible parts and custom fabrication matter more than documented service life.
- Look at commercial tracks when reliability, replacement parts, and known load ratings matter more than experimentation.
- Use appropriately selected industrial chain for a heavier design only after checking loads and component compatibility.
- Do not treat this prototype as a validated heavy-duty or human-carrying system; the published accounts do not establish those uses.
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