Ordered a new #41 48 tooth aluminum sprocket. Would have preferred steel but for the amount of fabrication we wanted we decided aluminum would be the best way to go.
Added 8, 1" lightening holes and 8 c'sinks for 5/16 flat head screws. Makes for a world of differnce in the look.
The hub adaptor is a neat piece of work. Thank goodeness for a CNC mill. This was fabricated from an aluminum block 5/8 thick.
The adaptor will bolt to the flange of the hub with 9, 1/4-20 flat heads. Clearance for the spokes added so we have a nice solid fit to the hub. Nut, washer, lock washer to secure it to the flange.
Left a ring of material proud on the adaptor to locate the sprocket bolted with the 8, 5/16 Flat Heads. The sprocket ends up being pretty close to flush to the end of the freewheel mount.
Mike