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Sorry I can't speak to your dilemma about the brake hat, but as for your sanity..... wellllllll......... you're still posting and moving forward with your build....... soooooo. you are still just as insane as the rest of us!!
I ran into the same problem with not enough keyway. I used Roosters trick and extended to keyway using a die grinder with several cut off wheels stacked together. Then took my time and extended the keyway all the way to the transaxle housing. It worked fine I have done several that way.
we used a small rotor and hyd brake from a junk pit bike. i welded the rotor to a 3/4 hub from tsc, made a bracket to hold the caliper to the transaxel and it all fit nicely iside the rear wheel.