I am thinking about making them by myself, just need to figure which way to take now. I could fabricate it in at least three different technics, but if there is a less effort demanding way based on using some existing components it could also make sense. For now my plan is to get some white tubing caps and see which of them fits. The rack rod is 6.3mm, the caps are available in 5.9 and 7.8 sizes. I would order them both and just see how it would workShaping up nicely. Find something cool to put on the rack ends. Maybe some little rocket valve caps.
My hub only works on a higher gear, i don't know why. I have re-hauled it like 20 times now, fixed the other issue with the brake locking, but still no success. When it is open it does work, but as soon as i close the hub it only works on higher gear. I have now ordered another one of same later model as mine to swap the guts and analyze the working hub and try to find the root of my problem once again.I've freeballed a Duomatic before because two of the bearing cages were toasted. It wasn't easy, but it sure worked well.
Repairing the planetary hubs in my opinion is the most challenging yet the most satisfactory part of bicycle building I will not stop until i make it work! I have found two more hubs like that for sale for 50$ for both and i am going to buy them on Monday. Then worst case scenario is if i won't manage to fix the hub laced in the wheel for some reason, i would just ask the guy who is building the wheels for me to exchange the hub for the older version i have. Housing dimensions are same, so same spokes would do, and repairing the older hub would be easy, since the only issue i did not yet address is the wrong bearing. I can not just swap the insides of the ones i have on my hands though, the shape and amount of the teeth of hub shell and planetary mechanism are different.Bummer on the duomatic hub, but the bike really look the part!!
If you can't fix the hub: just do not cycle uphill