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Join Date: Feb 2012
Location: Rochester, NY
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Bikes: Stewart S&S coupled sport tourer, Stewart Sunday light, Stewart Commuting, Stewart Touring, Co Motion Tandem, Stewart 3-Spd, Stewart Track, Fuji Finest, Mongoose Tomac ATB, GT Bravado ATB, JCP Folder, Stewart 650B ATB
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First thing I would try is a more current steep pressed dust cap found on HG freehub bodies. These are installed with the concave/cup facing out. Being steel one can tweak their OD rim with needle nose pliers. Better and older service focused shops might have an old hub or freehub body in their boxes.
Next up would be making a dust cap from some bit of plastic. With care filing a chunk pretty round won't be hard. Getting the axle hole centered might be harder (although as I think about this making the axle hole first and filing around that for the fit to the FH body makes more sense). A lathe is a wonderful thing... Andy
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AndrewRStewart