classic motorcycle forum

I wonder what is the world-wide annual demand for lightweight Albion gearbox sprockets? I have a sprocket box, so now I'll have to go out and look.

Leon

Unless you enquire you’ll never know how much spline cutting would cost. Again, it depends on the capability of the machine shop in question.
As for one-offs it is common practice for a business to have a minimum price for any job. If so I ask how many items I would get for that price. I might only want one but if I can get more for the same price I both have a spare plus others to sell/trade/barter so as to offset my costs. It’s amazing how people pop out of the woodwork when they find out you have this stuff.
You have to stop thinking like a hobbyist and start thinking like a business owner.

Given that I have been having various sprockets made in various numbers over a twenty year period it’s only possible to say the price is reasonable.
There is no ballpark figure as there are too many variables between individual circumstances. We don’t even know what country the enquirer lives in. All we know is that there will be an industrial transmission place not too far away and they can solve his problem.
I can also say it’s not worth the bother of trying to adapt sprockets from other applications. New sprocket blanks are heat treated to leave the centres machinable. Fully formed sprockets such as yours are usually heat treated throughout and a pig to machine. There is no saving in going down that track.
Having stuff made is a business proposition. It has to be reasonable for both sides. No business can make things at a loss nor can they be too expensive as that drives customers away. For repeat business both sides have to walk away happy.

I’m quite familiar with the EJ box. Albion boxes are common in the type of bike I favour.
Sprockets are not a problem. I have mine made. I enquired at an industrial transmission place who directed me to the machine shop that made their sprockets. Easy as that.
Sprocket blanks come as either “flat plate” or with a central boss. How the job is addressed depends upon the capabilities of the machine shop in question.
Take both your sample sprocket and the sleeve gear it fits on when you make your enquiries. Be organised and prepared to make a decision on the spot. Most firms dislike dealing with the average motorcyclist. They dither and moan and always cry poor. Be businesslike. We could start a whole new thread on why businesses can’t be bothered dealing with motorcyclists. They are their own worst enemy.
Tell us how you get on.

Hitchcock motorcycles is the goto place for Enfield stuff. They have a good website. All the 4 speed gearboxes as based on Albion even the internals and the clutches but the dimensions may vary. Bullet final drive chain is 5/8" × 3/8", I think the 250cc bikes used a smaller chain, might be worth checking.