Cool thread, I'm been so busy I am behind on the times here, its nice to some cool designs going through here!
I made my own belt sprockets for my Motoped and it really has been working out pretty good. They took me way too long to do since I had to mill them using a 5/32in end mill and just under 1in thick. I've been wanting to get a the 4th axis running on the mill so I could just use a stub mill to do them extremely quickly. I had also considered similar ideas to what you guys were talking about here such as the thin section of sprockets that would be bolted together. I'm currently running the 20mm wide 8mm pitch powergrip GT2 belt. I've pushed just under 10 HP through it and has not ever skipped a tooth.
Just FYI, Polychain and powergrip are two different profiles and are not compatible. Polychain is really the ultimate. I would love to run that and could get away with only 12mm wide belt.
I also am running not recommend size sprocket. I in the photo is a 14T and 15T, gates recommends no less than 22T. So apparently I will get advanced belt wear, but I'm at 270 miles so far with out any signs yet...
I didn't see the photos of these posted here anywhere:
Both are supposed to shed mud and have crazy torque handling abilities, very innovative design I thought.