[jman4747]

Originally Posted by DonRotolo

We're all shafted now and then.

We've digressed significantly. I think the OP has a better idea of how to work with Galvanized Steel, and aluminum versus steel probably deserves a thread of its own. Or?

I don't really have a problem with a materials science class in a thread now and then.

Also on the steel vs 7075 shafting thing, personally reducing drive train inertia is a priority and also reduces overall weight. Design wise I like to go a little heavy in the lower frame and keep all the scoring stuff up top light. Coupled with lightweight drive train parts and as few as possible. I can't tell you how much time I spent trying to get a 2" colsin to work so I'd only need a 4:1 of the CIMs.
PS I really like the torque/speed combo from 8:1 on 4" wheels. PSS really dislike drive train inertia.