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Printing as a possible alternative to machining a billet?
https://www.lfgss.com/conversations/287457/
... but I've no idea how much it would cost to contract out...
MrE
@Harry_C
@MCamb cheers for that, edited the post to suit
@Dogtemple rim will be an aluminium box section from here:
http://www.unicycle.uk.com/penny-farthing/penny-kits/54-udc-penny-farthing-rim-64-hole.html
I could buy the hub from there, but I managed to code the dimensions for square tapers into a CNC program at work, so could potentially be fancy and have a custom hub produced if I can track down a decent sized billet.
@Skülly I reckon being especially nice to someone like Sapim could get me some overly long blanks, although may need to get something tougher than standard (14?) gauge spokes and roll a thread into them