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I suggest you look at this thread. Or like Popshot wrote, the Viking tandem. Now, the Viking is an old desing, but it works. And with new tech it can be updated. Use modern 20mm shafted hubs, combined with 20" heavy duty rims and balloon tyres like the Schwalbe Big Apples and suspension...

Taper lock is another methode. But big, heavy and expensive.

"Industrial applications experience talking". Drilling straight trough the middle of a shaft/axle removes the most material and weakens it even a lot more compared to the simplicity. But if you go for that idea, roll pins, not bolts. And if you can't avoid bolts, make sure the threaded part...

Key and keyway would be the industrial solution.

Correct, 6mm is for 20mm shafts. 5 for 15mm. 10 is 3 or 4.

Lucky me, I have a 6mm broach for "keyway-ing" 20mm bushings.

Grubscrews for schaft "clamping". Industrial standard is 2 at 120° (of 90°) And for torque applications, a keyway please.

Over here, I mean "Corruptistan", where bureaucrats have €18K chairs and €2400 coffeemakers. Or in other words, Belgium. Where a blue collar person has to pay 75-80% of his wage in taxes.

Buying second hand over here is expensive. I have seen "supermarket bikes" being sold at prices higher than new....

Sorry, I'm at the Dortmund Intermodelbau faire.

I didn't bend those rods in bike applications. But Robot Wars has its own hazards. Using threaded rods as structural elements is contra-indicated.

Threaded rods are ment to bend. The thread is just a wrapped around bending line. A M10 rod is maybe as stiff as an 7mm solid rod.

Those batteries are a joke. Good for a kiddies toy.

And nowadays, we install more computing and communication power on our machines, by adding a small rectangle on a stand.

Take care, that kit is only the dif and motor. All the rest you'll have to source differently.

If I had the money, I would buy the car, remove the Merlin, and give it the real place it should be. Next to his brother in a flying , active Mosquito. Fun fact. With Roaming Robots (live event organiser with "combat robots") we had a few years at RIAT as an "attraction". The 2008 RIAT...

My commercial trike runs on 15mm schafts. Just a rod cut on lenght, and on each end a 20mm deep m8 hole. You even can find 15mm/20mm silversteel or even case hardened shafts* in industrial enviroments. *lineair motion shafts...

It is still a derailleur. Just protected.

Less than $120 each? I think, a RYD Andra 40 36 spoke rim, combined with these hubs are next to indestructable, and still be cheaper than $120 each.

You're asking for hens teeth. 36 spokes is usable. And 15mm or 20mm axle hubs are easier to source on aliexpress or simular.