Freewheel threads too small for bike

I know the reason steel sprockets and shafts was used is economic, Sick Bike Parts was a business not a hobby. But I was doing a "feasibility study" of a simple two speed dogbox for these kits and was surprised to see how cheap and common aluminum sprockets and shafts are.

Mainly looking at grainger for what's off the shelf, I know 6061 is not the best for fatigue resistance and service life but its so much easier to machine than tool steel.
 
I know 6061 is not the best for fatigue resistance
Why not just use 7075 T-6 then...If it is good enough for missiles and F-16s and other military aircraft it should work great for what you want it for...Any parts I had fabricated for my bike were fashioned from that...Front motor mount and the rear disk brake caliper to frame adapter.

They will outlast the bike itself...lol.

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Fabricated Rear Caliper Adaptor IMG_0347.jpg


Another view of rear caliper adaptor.IMG_0350.jpg
 
I know the reason steel sprockets and shafts was used is economic, Sick Bike Parts was a business not a hobby. But I was doing a "feasibility study" of a simple two speed dogbox for these kits and was surprised to see how cheap and common aluminum sprockets and shafts are.

Mainly looking at grainger for what's off the shelf, I know 6061 is not the best for fatigue resistance and service life but its so much easier to machine than tool steel.
On my SI double freewheel triple chain ring shift kit the bottom bracket cups are aluminum and this is the only internal part that's aluminum. All 3 chain rings and the engine drive sprocket are steel.

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