well I warped out the keyways on the shafting a couple weeks ago, and have since put together and machined a new shaft design.
I guess I should believe the computer next time
The new design has permanently welded on brake and sprocket mount and splined cv hub connections allowing the bearings to be removed if necessary. The shaft is now 1 3/8 inches thick and was made out of two of these to save machine time:
http://www.ebay.com/itm/291121564506...%3AMEBIDX%3AIT. They are coupled by a precision bored collar in the center so both ends are splined. The CV adapters were bored to accept splined couplers matching the shaft and welded to them. the sprocket and brake hubs were bored to near perfect angular runout before being welded to the shaft.
Doesn't seem to have any issue chirping the sticky automotive snow tires when cornering on pavement. or ripping full throttle 2nd gear doughnuts on gravel. Soon I will take it to the dunes for a real test, just need to do some serious upgrades to the trailer
