I think for the sake of maintaining momentum I will stick with my timing belt plan in this case. I also have a ton of castor wheels to use that won't mount very easily to any live shaft, but are perfect for dead shafts. See Edit.
Tonights progress, mainly focused on a new layout, fitting things in better and overall design considerations.
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Edit! Just saw that thread about making your own hubs from linear bearing mounts..... that seems like a real nice option! Would I need a keyway as well? Or would it clamp tight enough as is? Maybe that is a better solution than the belts after all.
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