[coreyjon]

Last year, my ascending system used two globe motors. I did what you want to do, I bored the two ends of the main drum with the shape of the output shaft, the motor just slid in, and that was it, no set screws to worry about. It was however, a pain in the butt to mill by hand (which is what I did) - but it is possible. Of course, if you could, and the design permits (mine did not) you could always use wire EDM, or water jet like the above person mentioned, also do not forget about CNC milling, as it would have worked for what I needed it to if we had a CNC mill large enough. I think using the technique you used in the past was good in a pinch, but I would constantly be worried about the set screws. Globe motors rock, and I had two, because everyone was afraid to use them (no side loads are tolerable) - so remember that!! don't just cantilever the gear without proper shaft support, or you will eat the gearhead in a second! Good luck with your project.