TejanoTrackie 

First off, I did not tell the OP to F-whatever nor was I in any way rude. Was I curt and to the point, yes. My objection was that the OP appeared to make no preliminary attempt to seek out as much information as possible before posting on this forum. No doubt the forum member who replied with the link to the drawing found it by "googling", so why couldn't the OP do the same? Also, most of the information the OP is seeking is common knowledge, and not in the same realm as "What airfoil section does the C-130 use?", which may be proprietary or even classified. As a practicing engineer, I often sought the advice of my colleages in areas where I lacked expertise, but I did the basic leg work myself rather rely on them to do all my work for me. Had the OP posted that he or she had already done the basic research, and was now seeking specific detailed information to complete the task, then I would have been more receptive to providing assistance. Finally, the OP is an engineering student in the learning phase, rather than an engineering professional in the practicing phase. As a practicing engineer, I was under tight schedule constraints to obtain results in the most expeditious manner and did not have the liberty to spend time engaged in research or "reinventing the wheel." OTOH, the OP is a student who needs to spend the time to learn design, and perhaps waste some time in order to learn the design process and how to evaluate the issues that are relevant. Simply copying a design drawing into a CNC machine is not engineering design.

jmartinez

I'm going to jump in and add the opinion of another engineer. Some of your questions your questions relate to specifications and some are design questions.

My advice is to first buy the off-the-shelf parts you plan to use such as the axle, cartridge bearings, spacers/locknuts, cog and lock ring. Take your calipers and get the measurements you need. Once you have the dimensions laid out, it's pretty trivial to design a hub shell around the parts.

If you want a hub that is going to be as light as possible instead of just looking cool, you task will be a bit more involved.

As for flange thickness, wall thickness, and chain clearance, these are just part of the design exercise. Take a look at some of the hubs on the bikes you've built and work out the flange thickness from there. Wall thickness of the hub shell will depend on material and geometry and you should work that out on your own as you sketch out your design.

Have fun, make a few so you can keep a set for a memento and ride the heck out of the rest.