I appreciate everyone's continued feedback. I am reworking the design with it in mind and will have a revision ready later on today.
Already, it's looking better, though there's obviously a long way to go.
I am pretty sure this can be assembled.

I moved the assembled wheel clamshell into place from the outside in the model and, while it was a tight fit, it seemed doable.
Quote:
Originally Posted by Andrew Lawrence
Why not go with belts?
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Ignorance, mostly. There are lots of gears and sprockets available with the "FRC bolt pattern," but not so with belt pulleys. There are the AM kit pulleys, but I don't like the ratio.
Our mill and lathe are often bottlenecks in our fabrication process, so I try to design as few parts as possible that require milling or turning. So, until belt pulleys are sold with that 6-hole pattern (and versakey! ...hint, hint), we'll not head down that path.