Hi Bill,
I really appreciate the reply and feedback. I'll definitely consider using Jet Nuts for the fasteners! Even using red locktite, the fasteners may work themselves out, or perhaps galling will occur. More often than I'd like, I've had caliper mounting bolts work themselves out through NVH on my Datsun 280ZX Turbo. The roads in Southern California seem to shake our cars to pieces much more than up here in the Pacific Northwest. I need to purchase a safety wire-tie setup so that this won't happen again:
http://speracing.com/images/Safety_Wire2.jpg
I'll rework the design to recess the hat as you recommended. I think you're right about ensuring concentricity via "hub-centric" with the hat versus "lug-centric" with the bolts.
I was relying that a majority of the shear load would be taken up by the friction between the rotor and hat mating surfaces. If there was no preload or "pre-torque" in the bolts, I would definitely be concerned about the bolts shearing off.
Cheers and again I appreciate the feedback!
Sincerely, -Hugh
Hugh Henderson
QA Engineer (Fusion Simulation)