How far I am on this subject:
Thanks to @UniGeezer it took 5 minutes to put the hub loosely into a wheel, this was obviously on 03.06.25 and shows my slow progress until now.
The freewheel clutch is a solvable first problem:
Welding would certainly destroy the sealing O-ring and hardened stuff is usually not weldable. Re-machining the clutch section is feasible, i.e. with a flange to mount conventional sprockets:
The 2 problems are shown on the next picture:
a) the freewheel clutch (in the center)- can be welded or machined
b) 2 of the 4 asymmetric and distinct (height and backside groove) CVT ball clamping rings- they have to be machined to be symmetric.
It was disappointing to see that the 4 rings are not equal, what just takes longer time.
Drawing of the asymmetrical original:
Drawing of the symmetrical replacement:
Go for it:
This is the raw ring. It is ready to be milled on the round table to get the symmetrical up and down ramps. Milling by hand. A single mistake and you start from the beginning.
I noticed that the width of the 4 rings is not equal. So I created a fixture to plasma cut the next rings to become faster:
I take standard ST37 steel for the rings, which can’t be hardened. The balls directly run on the rings, so in reality the rings should be hardened. When hardening steel, it will distort and should be grounded to dimension, what I can’t do.
Till now I haven’t dismounted ring 3&4 yet- just no time to loosen a single screw. Many more projects, so I didn’t find time to go on. Don’t wait for me to continue.