As far as the knockoff, I finally got around to filling the knockoff with Amazing Resin and casting the hurricane nuts into place. Interesting, the hubs on the rear wheels are not flat. They dome a little bit; maybe built that way, maybe spoke tension causes it; I'm not sure. The issue this caused was making the hurricane nuts sit canted as they were casted into the knockoff, as I bolted the hurricane nuts to the hub and sat the wheel over the knockoff as I was casting the resin.
Alas, no pics of the process, but I will take some when I do the second knockoff.
Now onto a story with pictures (yay!).
In order to clean up the rear, I was determined to package the disk brakes inward. This caused an issues-a-plenty in that not only did the disk and caliper have to fit in the narrow space between the axle gears, but the calipers had to clear the freewheels/chain (creating a minimum diameter outward from the axle, and making the 120mm disks I purchased previously too small in diameter), and also the Meridian's outer 'hoops' that locate the axle housing (creating a maximum diameter of roughly 155mm).
My answer was a set of 150mm disks I found on ebay, intended for motorized scooters. They are 2mm thick, so the calipers I have already will work; BUT the disks hub hole and bolt pattern are too large to fit the disk hubs I purchased from Staton. My spare parts supply is beginning to stack up!
To remedy the hub issue, I purchased two 22 tooth axle sprockets from Husky, meant to fit the 17mm axle that I also puchased from them.
Two issues arised marry the disks to the sprocket hubs: #1-the outer diameter of the sprocket hub was a wee bit to large fit the disks; and #2-the bolt pattern diameter on the disk is too small to locate the nuts needed to secure the disk, as the nuts would hit the sprocket hub before lining up.
To solve problem #1, I bolted the hub to the axle, and had my wife do her best impression of Giligan powering up the coconut radio as I ground the od of the sprocket hub with an angle grinder.
Schweet!!!