JEB wrote:I would have ground all the teeth off the sprocket (dust shield on shaft, run motor to make it round) then grind a new keyway on the finished dia, to fit a keyway to the aluminum hub id of the freewheel.
Also a 72 tooth sprocket (11.750"od) would bring the crank rpm closer to normal crank speed for the average person, 80rpm~ (5:to1~).
The crank spins over 100rpm right now, however I seem to get a good range of speed out of this as long as I am in the proper gear. Sadly I don't pedal very much with this set-up except from a stop. I can pedal with this, however I need to put it in a faster gear.
Probably would have been stronger to get a new keyway, however I found my design to be easier to do with my basic power tools at home (grinder, drill, jigsaw, rotary tool). Its hard to get precise cuts without the proper tools.