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> OK engineers! Let the hole shooting begin!
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Scott, My training is as an electrical, not a mechanical engineer, but I will add a few
thoughts.
The spline design used on the Alpine is apparently at the strength/design limit for the materials and design used. To make it able to handle higher loads one could improve the materials strength or change the design. You could change the spine shape, such as fewer but larger triangular shaped splines, or larger "buttress" shaped splines (think of the difference between an Acme thread and a conventional inverted V thread); either change would offer larger load carrying capability.
Or you could work to change the material strength. I am not sure what metal you would go to to get higher strength than the stock steel, but I am pretty sure that epoxy will not meet that need. In addition, as you pointed out, epoxy resins lose their strength and soften at a few hundred degrees F. This is not a material property desired on a wheel hub, where the conversion of kinetic energy into heat by the brake pads can make the hubs quite hot.
Someone mentioned a few months ago that back a few decades Dunlop (I believe) , when faced with this problem, went to a pin approach. Maybe this is a workable solution ? A couple of tapered pins would resist the rotational forces with the existing spline and locking hub serving to restrain the hub co-axially.
-Roger