How to mark holes?

I dismantled the rear hub ... which has a large ring on each side (it's just pressed on) ...

So when I tapped the ring off ... I discovered (to my delight!) that it was almost the identical size of the AN970 Washers that I bought from Aircraft Spruce.

I just laid the ring on the washer ... used one of those fine point Sharpie markers thru each of the spoke holes ... giving me a washer like the one on the bottom. Then I used a needle punch to mark them for drilling.

Hey! This is progress!

Drilling Jig for Hubs & Axles

I made this little jig so that I could consistently and easily drill the corresponding holes in the hub and the axles. The jig is made from a piece of old bedframe. Notice that when I drill the hub, I insert one of the AN970 washers

that has been cut to fit the "V" of the jig. When drilling the axle, I remove the washer so that I can accurately drill the correct location that the hub would fit on the axles with just the tip of the axle showing with the outside washer on. Do you understand what I just attempted to say? Ok Fine. :0)

Hub Mock-up

After removing the inside seam ... the axle rod slides smoothly thru the black pipe and the AN970 Flat Washers. Since the washers don't have the spoke holes drilled into them yet, I'm not about to weld the hub together.

Removing Inside Seam

To get rid of the seam on the inside of the pipe ... I started with my Dremel tool and a small grinding stone. I went back and forth across the seam to cut it down. I did this from both ends. Then I used this monster-big rattail file that is about 5/8" in diameter to wear down the ridge in the part I couldn't reach with the Dremel. When the file slides easily thru from either end ... it slides beautifully onto the axle bar.

Tube Cutter

A tube cutter is a handy little tool that should cut a perfect circle around the pipe so you have a reasonably flat end ... I say should because mine wore off a tiny spot and started trying to cut a spiral ... at which point I had to go back to using the hacksaw.