Track Hub design
#26
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Though I'm not sure how personally asking people who are somewhat likely to possess the knowledge isn't a viable way of gathering relevant information. If someone comes to me and says "What airfoil section does the C-130 use?" I'm not gonna say "Go look it up...and F- you for being lazy". I'm going to provide the answer if I have it because appealing to expertise is a great way of gathering information. It's not spoon-feeding, and there's nothing inherently honorable about arriving by an answer in a harder way than necessary.
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I think this will do. Thanks!
The thing is that it's easy and possible to find thread sizes, but try to find the information about how many turns it has to have. What is the needed distance from sprocket to flange so the spokes don't touch. How thick the flanges need to be, what is the needed wall thicknes in the middle of the hub? There are lot of questions and a googles link to wikipedias flip/flop hub just doesn't do good enough..
The thing is that it's easy and possible to find thread sizes, but try to find the information about how many turns it has to have. What is the needed distance from sprocket to flange so the spokes don't touch. How thick the flanges need to be, what is the needed wall thicknes in the middle of the hub? There are lot of questions and a googles link to wikipedias flip/flop hub just doesn't do good enough..
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.