Wheels #1: In the begining

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Blog entry by robscastle posted 06-19-2018 09:14 AM 948 reads 0 times favorited 8 comments Add to Favorites Watch
no previous part Part 1 of Wheels series Part 2: Progess has been made »

I guess if you follow the cartoon series BC you will have possibly seen what may have been the very first wheel ever made. (humour by way)

I have been watching all the craftsmanship work by a few of the group of LJs that excell in making wheels.

Many years ago, 2013 I did actually make some wheels (about the BC level skill too I might add.

They were fitted to some wooden toys, of which I still have but are about to be relocated to a friends place to support the birth of their son.

Anyway after seeing htl’s post on spoked wheels I thought it was time I developed some more advanced wheel making skills myself.

My project is going to be a spoked wheel from my motorbike, however there is a catch its a mag wheel with only 3 spokes!

So I set to work with a piece of timber I found which I thought was suitable.

I set up my drill press checked everything was aligned and set to work.

No sooner had I started Wheel No 1 I realised my alignment setup was not exactly where I wanted it. So rather than stop and re do everything I simply chiseled out a section to allow the sawdust to exit, and continued cutting down about half way. ( If you wondered why I did this the reason will be evident in another picture)

I then adjusted the setup and started wheel No 2.

Repeating the same process as wheel No 1 I continued.
Only this time its now correctly aligned.

Now observe the pile of sawdust, its massive! and if not allowed to exit the cut this is what makes cutting with holesaws a long protracted exercise and may result in burning both the holesaw and the timber.

I think Both Kiefer and LittleBlackDuck have posted videos on various methods of extracting the sawdust.
They cover a few different methods and are worthwile reading if you are contemplating entering the circle of wheel makers. Check them out.

Note:I cannot locate them at the moment but if I can find them I will add both as separate links later.

Update 1 Located LBD Post.

Update 2 Located Kiefers “Poshttp://t” its actually referenced within LBDs post.

Anyway moving right along I found the piece of timber I used could make 5 wheels so 5 it was.

Once I had all the cuts on side 1 completed it was simply a matter of flipping the material and cutting the wheels completely through. I again had to chisel out wheel No 1.

This is what was left of the parent material.
You can see the feather edge where the hole saw met in the middle.
I also bagged up the sawdust just in case I decided to get a pet duck so I could make a nice bed for it later.

Now the raw wheels together.

I was pleased with the results I got. Now for something new, working out how to sand them round.

I set them up on my disc sander but was not all together happy with the results, so I stopped and went to figure out how to make the actual tyre and hub.

It was after checking the real wheel I realised the blanks I had made were “way to wide” for what I was trying to achieve.

Disapointed with this, and the fact I need to get a better sanding method I shelved the work for the time being.

I will get there eventually !!

-- Regards Rob

8 comments so far

View pottz's profile


16813 posts in 2064 days

#1 posted 06-19-2018 01:30 PM

all that and you shelved it,cmon buddy get back on that horse and ride.also be careful LBD is allergic to certain types of wood dust,you dont wanna make him sick-lol.

-- working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

View Boxguy's profile


2897 posts in 3347 days

#2 posted 06-19-2018 07:29 PM

Rob, as the Sir Hillary of woodworkers I am sure you will solve this problem too. I can tell you from experience that is is not wise to trap the wheel against your sanding belt. I found out it is a great way to make way too much blue smoke.

-- Big Al in IN

View crowie's profile


4571 posts in 3031 days

#3 posted 06-19-2018 10:11 PM

Okay Rob, I’m interested in seeing what you’re going to make to fit there wheels to!!

On the “too thick issue”; you could recess the wheel with a forstner bit to create a hub…

-- Lifes good, Enjoy each new day...... Cheers from "On Top DownUnder" Crowie

View LittleBlackDuck's profile


7076 posts in 1900 days

#4 posted 06-19-2018 10:12 PM

rc, FAIW

I found that after you start the cut drill, a relief hole (fosters… no forstner bit is gooder) kissing the kerf… naturally on the waste side… which I always find is the opposite side to where I drilled my initial relief hole.

That way you don’t have to worry about exact holesaw placement Only hassle is you might need to swap drill bits momentarily, however, that may be less hassle than moving the piece to chisel…

Only thing I hate about holesaws (amongst all the other hates)... if you want a 120mm hole, no matter how long you soak that blade… it just refuses to shrink.

PS. Like the tip if harvesting saw dust… for those soft egg landings.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View robscastle's profile


7878 posts in 3284 days

#5 posted 06-20-2018 12:34 AM

Pottzy:- It will happen just a short lull in activities until I can get it all in one pile
Big Al :- Yep your right, Incorrect sanding process Mk2 confirmed
Crowie:- I may not even make anything for it certainly not the bike purely experimentation at this stage. Regarding the width I am going to make a jig and bandsaw them down.
LBD:- Ta I added the project link

-- Regards Rob

View htl's profile


5427 posts in 2239 days

#6 posted 06-20-2018 02:41 AM

Very interesting and them’s going to be some big wheels!!!

-- An Index Of My Model making Blogs

View htl's profile


5427 posts in 2239 days

#7 posted 06-20-2018 02:46 AM

I love the way all the bases are being covered on this site, with not just models being made but some way cool and cute toys builds also.

-- An Index Of My Model making Blogs

View Joe Lyddon's profile

Joe Lyddon

10963 posts in 5132 days

#8 posted 06-20-2018 04:35 AM

I can hardly wait to see where this is GOING… :)

Very COOL.

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:

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