With the axles finished, we can start assembling stuff to verify the motor mount design.

The keys for the gears were cut from a piece of 3/16 spring steel keystock.  Eight pieces 0.75 in long, and two pieces 1.0 in long.  Each was lightly filed after cutting to length with a hacksaw in the vise.

Each shaft sticks out 4.25" to allow 0.125 clearance to the bearing and 0.125 for the axle to stick out of the wheel hub.  The core of the wheel hub is 4.0 in long.

The chains were cut to length a few weeks ago and bagged in light oil.  After assembling all the sprockets, shafts, keys and wheels the setscrews were tightened on the sprockets and the bearing blocks.  Adding the chains and the master links, it's starting to look interesting.  Here are a couple of views:

The motor mounts are next.  The jig plate from Friday was cut down into two long strips using a recip saw.   Cut nice, but somewhat inaccurate and crude.  I cut them wide then milled them clean and square to 4.25" each.

I need two pieces for each side, one 3.125" and one 7.00" long.  I could do the recip again, but it is loud and messy.  I don't have a bandsaw, but I know you can cut aluminum with a circular saw or a table saw. Both of these are kind of dangerous if the material kicks out, or if the saw kicks out of the cut.  However, I do have a 12" chop saw!  The blade rotation loads the part against the fence so is much safer.  A quick trip to Home Despot yielded a new blade:

It's a Diablo D1296L.  The pic is the right one, but mine says "Laminate/Non-Ferrous" on it - they are the same blade.  A high tooth count triple chip blade with a narrow kerf.  It cuts through the jig plate like "butta", but it makes a storm of fine aluminum chips.  Even with the dust collector running, wow, I have some vacuuming to do...

I cut the two pieces off with just a smidge oversize and cleaned them up in the mill.  If I wasn't too particular, the cut from the saw would have been just fine.  It truly is amazing how easy and clean it cuts.

I printed the drawings for the mounts, all the bits are cut to size, maybe tomorrow I'll bore all the mounting holes, slots and such and get them together.