I modeled the drive train off of ideas behind of 254's drive train, and 968's tensioner.
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Why couldn't the wheel be only two pieces by incorporating the hub into the wheel itself?
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I designed the wheel so that it could be swapped out easily. All we have to do is to remove the six bolts, and the wheel is free to be swapped out. Also, one of our sponsors is a sheet metal manufacturer. They can easily cut out the 5 pieces of sheet metal that make up the wheel. The wheel has an 1/8 th inch thick rim, a 1/4 inch thick spoked section, two 1/4 inch body sections, and another 1/8 th thick rim. They would then spot weld these together in that order to make the wheel. By incorporating the hub into the wheel, we would have to start with a larger block of aluminum and wouldn't be able to make the wheel out of sheet metal.
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We decided that we should use 2 chains one mid wheel to front wheel and one mid wheel to back wheel. in case one breaks you still have 2 wheels driving.
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I am doing the same thing. You can see the two sprockets on the main drive shaft in the other picture that I posted. Thanks for the advice on tread wear
Here is a render of our tensioning device. Once again, it is made out of sheet metal.
