Originally Posted by
jPrichard10
This has hit on an idea of mine.
A lot of the nicer cassettes have the larger sprockets riveted to a spider, and there's no reason someone couldn't make a spider that interfaces with one of the freewheel bodies.
Well, there is a reason: there's no profit in it. And there's so many different freewheel interfaces, it would be hard to choose which one.
But it could be done, as long as your big cogs are large enough (no corncobs).
There are a few possibilities that might be explored, including the fitment of a one-piece PowerDome cassette onto a freewheel body.
The one-piece steel PowerDome uses a removable alloy large cog to interface with and transmit torque to the freehub body, but this one (thicker) cog could be machined out to the larger spline pattern of any freewheel body. The small end of the cassette would then need to just locate (no spline needed) to the smaller end of the freewheel body, with perhaps the freewheel's original smallest threaded cog holding things together.
But I gave up on this idea because the PowerDome cassettes are very expensive and were offered in a limited range of sizes.