We’re using Honda Civic wheel hubs, wheel bearings, CV joints and axle halfshafts. They’re available everywhere, cheap, and light, and by using them we avoid having to cut matching pairs of splines. The wheel hubs are drilled for lightness and tapped to accept the wheel drive pins, then the two outermost pieces from two scrap CV joints are cut down to use as bearing retainers for the front wheels. Rear axle halfshafts are used in stock form, but extenders from the halfshafts to the differential will have to be fabricated later.
When cutting the CV joints I found that the contact faces are hardened some way into the joint, making cutting almost impossible (by which I mean “impossible”) beyond a certain point, even with carbide cutting tools. If they are heat-treated, maybe there’s some way to reverse the hardening? It’s probably something more exotic than that, though, as the hardening was highly location-specific.
Starting to modify the wheel hubs. Mounted on the rotary table on the milling machine.
Finished wheel drive pin modifications
Wheel drive pins and brake hat fit! Note how the brake hat has been reduced to a lightweight spider.
Test fitting into front brake disc, inner view
Test fitting into front brake disc, outer view
Cutting the seat for the stub axle; adding more lightness.
Dowel-pinned the stub axles to the wheel hubs so they don’t turn when removing lug nuts.
First test fit into road wheel, inner view. It fits, yay!
Test fit into road wheel, outer view.
Trimming off the excess CV joint for front axle assemblies.