Bill please talk me down off the ledge...
I was going to save this for later but I will spill my guts. I've seen absolutely amazing creations from Captain Rick, Jarus and other (the 4 motor car is amazing) in the AWD arena. But I wanted to see if it might be possible to build something that might actually be competitive with respect to modern Cam Am cars. And after pursuing this for over a year now (ok, two), I realized that the major issue is the motor to driveshaft coupler. Specifically with a modern motor spinning 40K+ rpm, any imbalance in the coupler will result in MAJOR chassis vibration. And eliminating this vibration has proved impossible with everything I've tried including very light weight 3D printed plastic couplers.
Forward to plan B ... no coupler and this obviously means a motor with a long buttocks (slot blog edits the obvious word choice) armature that extends up to the forward gearbox. So now I think you can understand the need for perfect alignment. I understand your questions regarding an iron based material as the magnetic hysterisis was something I was concerned with as well. But in 3D printing, printing in steel is about 50% bronze (not iron) and worse yet, the results are very questionable in terms of dimensional accuracy ... plus or minus 5% error. Nicht sehr gut.
So I asked John H about this and he suggested that the iron content might not be that important in a strap motor as there is no iron extending past the magnets to extend the b field. Furthermore we now have available cobalt magnets rivaling MRUs in b field strength. I know there is lots of conjecture regarding all this but I was really more interested in trying it out to see for myself. So what if I make a motor with an aluminum can (very strong and very dimensionally accurate) with modern magnets to provide ample b field. Will this work, I won't know till I try it? In the mean time, the journey is proving to be a lot of fun.