The First Pieces Come Together!

This project is so involved that I will have to post about it in sections.  Up until now, I've built a jig to locate the new suspension, removed the old axle and leaf springs and cut out one of the battery boxes.  Here is the jig:

Today, I did the first machining to adapt BB's wire wheels to the Honda spindles.  As I mentioned before, the dimensions were already quite close so there wasn't much material to remove, but boy was that material tough!  Being a wheel hub and axle, I'm guessing it was a chrome alloy in the mid 20's Rockwell hardness.  Carbide cut it by one horsepower struggled to make enough torque!  Here is the set-up in the four-jaw:

After about 40 minutes of tapping and adjusting, I got it within 0.001" run-out radially and 0.002" axially.  I had to remove the flange and clean-up the ID to be a slip fit on the Honda spindle.  The main problem was to cut out clearance in the center for the spindle nut.   Two hours later, here is the finished geometry:

After drilling holes to get from 4 lugs to 5, here is the comparison of after and before.

And it fits on the spindle!  Now I can mount the wheels and get them lined up in the jig.  Progress is slow but steady and soon we will be having #funwithcars!