Well, it's been a while, but finally here's an update on the project.
The first thing that had to be done was to fire up the engine, and see what we're dealing with.
So I started out with making a solid stand for it:
Clamp it down and hold on tight...
To say we weren't disappointed by the sound would be the understatement of the century. We were standing in a riding stable, and the next day the owner told me that the horses that were standing in another stable nearby started panicking when we started the engine!
So, let's continue with the rear-axle.
The first thing that had to be done was to make the pinion and drive axles and connect them to the gears. The pinion wasn't too hard to do, because the gear was big enough to simply screw it to a flange.
The drive axles were harder to connect, because the diff gears are a lot smaller. At first I thought of simply welding the axles to the gears, but in the end I decided to put a pin through the axles and mill a slot in the gears.
Then I made the axle-housing. The diff and the axles run on seperate ball bearings. On the outside the axles are held in place by a circlip, so they can't move in or out.
I made a couple of flanges to fit the drive axles. The rims will be mounted to these.
And this is what it looks like with the tires mounted:
Now that's finished, I can start on the hardest part of this project, the clutch.