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Yeah, I agree in principle. The issue is cost, as you say. This is really designed to be a cheap build, if it comes to it I'll just use a tensioner. The other issue being that I wanted to be able to use all the wheels I already own which is self defeating if I have to build a new wheel to make it work. Appreciate the input though.
ThePeginator-
I ran a magic gear on one of my frames for a while. I used the same link that you posted to work out the gearing. I had to run it with a BMX half link chain to get the gear to work and I was totally happy with it. Two things to check are
1) that the chain is long enough if you go half link
2) that you are happy with the available gear ratio - I think my only choice was 48 / 18Looked like this (ignore the bars - they were swapped for risers immediately afterwards)
Aroogah
You have other solutions to run ss/fixed without any chain tensioner with vertical dropout frams which are eccentric bottom bracket and excentric hub. I have the latter from White Industries (called ENO) which is also flip flop, works very well and is really really easy to set up to have a chain well tensioned. It is a bit costly but there is currently one for sale on here for a much more reasonable price by @Fabs if you want