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me and my dad have done that to many times. but we finally got it right about 3 years ago it all comes down to how you grind it down we use a big grinder and then get the track thats on the ground and roll it in it a cut what you see is getting caught in the cleats.
That's my third set I've built. No doubt it don't get any less labor intensive. I have had very good luck just cutting enough relief in them with a razor knife(with a brand new blade and change them frequently). Those were for Jimmy Newtons buggy. We built ours 12 tooth cogs last year and we sold the 15 tooth ones we built 2 years ago. It amazing how much HP you need to make the 15's really work for you. Our buggy ought to live up to it's name now with the new engine and 12 tooth cogs. We should be as it's named ("GET TO GETTIN"
that magnetic drill press is the sh!t !! It makes the job WWWAAAYYY easier. Imagine trying to hold a half inch drill motor and drill thru 7 inches of rubber with a 2" hole saw!