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I won't engineer the part (except for the CAD work) as it's not my field of expertise. Why do you think the bearing will fall out under braking ? I was under the impression that under braking (and heating) the thermal expansion would exert even more pressure (preload) on the bearing. Here you...

Thanks for the input! My car is half of a road car and half of a race car. I'm at 750kg now and trying to get to 700kg.

I know that wheel spacers/adapters are made of aluminum, but could a wheel hub made of aluminum too ? I haven't seen ali hubs for cars, only for motorcycles. This could be a great way to reduce un-sprung weight and rotational mass. Are there any reasons not to use aluminum (like 7075-T6)...