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Bolt through hub and shaft
Of all the methods mentioned in this thread, the one we probably use most frequently for attaching a hub to a shaft is to drill and tap through the hub and shaft and use a cap screw and nut. We have used 10-32 bolts for 3/8 shafts and it has been ok.
I can't say we have never had a failure in the form of a sheared bolt, but it is very rare. I suspect that in the case of the few failures, the drilling and tapping were less than perfectly done.
When we have two sprockets next to each other with the same center, we normally bolt through sideways with appropriate spacers. This is very reliable.
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Team 45, TechnoKats, 1996-2002
Team 1062, The Storm, 2003
Team 233, "The Pink Team," 2004-present
The views I express here are mine, and mine alone, not those of my team, FIRST, or my previous teams.
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