On second thought ...

After thinking about how to handle the torque transfer from the drive axle to the sprocket cassette, I decided to go the more difficult but more elegant route. I had intended to use a kart hub to handle the torque load(previous post) and afix the cassette housing to it -- also sleeving the shaft a bit since the cassette's ID was slightly bigger than our axle.

After sleeping on it I decided that I would build an indexing jig and spline the shaft itself. By custom milling both the keyway and the keystock, I could size the keys to handle both the radial loads and the torque.

I started with a round piece of plyood and using my previously contructed hub holder created a indexed wheel.

I set up a little marker system off to the side of the mill table and used this to locate each spline location on the axle. Milling ensued.

Custom milling the keystock.

I left enough room in the keyways to move the sprocket group back and forth for perfect alignment. The shaft collars are only used to keep the sprocket from sliding back and forth on the axle.