Jibril
I picked up a 316 Stainless Steel 20mm shaft to mount the final output gear on as the Titanium shaft needs some machining to make fit the gear (it looks to be 0.5mm too thick) and finally have been able to drill the mount for the shaft. In a surprise, it turns out I hadn't drawn the CAD wrong, just what it looks like on screen threw me. The CAD drawing was tight, this is what it looks like with me holding the gear up before drilling the panel...

clearence.jpg

...and here is what it looks like roughly mounted, a 39.88:1 gear arrangement.

gears_roughly_mounted_900.JPEG

A test spin shows it all works so the next stage here is to get all the bearings mounted, get the other side of the carrier made and work out how to fix the gears on the shaft. The smaller gears have grub screws in them but the big gears are plain bores. Given that I am still planning to use Grade 5 Titanium with these steel gears, I imagine getting a key cut in the shafts and the gears itself would be the way forwards here?