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| | Select the material, a hard wood like birch, walnut or oak are best for wheels. use pine for set up and testing. | | Select the material, a hard wood like birch, walnut or oak are best for wheels. use pine for set up and testing. |
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| - | Size the material to 1/2" x 3.5” x 3.5”and locate the center, Figure 1 | + | Size the material to 1/2" x 3.5” x 3.5”and locate the center. |
| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=466[/IMG]]
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| - | Use a 3” hole saw with a 1/4” pilot drill, and drill 1/2 the depth of the material. Flip the material over and drill the remaining depth. This avoids tear out of the material as the hole saw penetrates the opposite side. Figure 2 | + | http://woodworkerszone.com/wikigallery/d/3631-1/Figure+001.jpg |
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| | + | Use a 3” hole saw with a 1/4” pilot drill, and drill 1/2 the depth of the material. Flip the material over and drill the remaining depth. This avoids tear out of the material as the hole saw penetrates the opposite side. |
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| | + | http://woodworkerszone.com/wikigallery/d/3634-1/Figure+002.jpg |
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| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=467[/IMG]] | |
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| | The inside diameter of the hole saw will become the outside diameter of the wheel, Leaving you a 1/2” x 2 7/8” diameter blank. Drill with 1 3/4" hole saw 3/8” deep to form the inside of the tire rim. Leave 1/8” of material in the bottom to form the lip the spokes will rest on. Use a mini lathe to shape the tire and rim, depicted in Figure 3. | | The inside diameter of the hole saw will become the outside diameter of the wheel, Leaving you a 1/2” x 2 7/8” diameter blank. Drill with 1 3/4" hole saw 3/8” deep to form the inside of the tire rim. Leave 1/8” of material in the bottom to form the lip the spokes will rest on. Use a mini lathe to shape the tire and rim, depicted in Figure 3. |
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| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=468[/IMG]]
| + | http://woodworkerszone.com/wikigallery/d/3636-1/Figure+003.jpg |
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| | This forms the lip required for the spokes to rest on when the hub is glued in place at final assembly. | | This forms the lip required for the spokes to rest on when the hub is glued in place at final assembly. |
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| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=469[/IMG]]
| + | http://woodworkerszone.com/wikigallery/d/3638-1/Figure+004.jpg |
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| | In figure 5 flip the blank and use a 1 1/8” hole saw to remove the hub from the center section. The inside diameter of the hole saw is 1” in diameter and becomes the hub. | | In figure 5 flip the blank and use a 1 1/8” hole saw to remove the hub from the center section. The inside diameter of the hole saw is 1” in diameter and becomes the hub. |
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| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=470[/IMG]]
| + | http://woodworkerszone.com/wikigallery/d/3640-1/Figure+005.jpg |
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| | Figure 6 has the hub removed showing the lip in it’s final form, 1/8” thick 1/8" wide. | | Figure 6 has the hub removed showing the lip in it’s final form, 1/8” thick 1/8" wide. |
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| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=471[/IMG]]
| + | http://woodworkerszone.com/wikigallery/d/3642-1/Figure+006.jpg |
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| | The edges of the tire are rounded off using a 1/8”radius router bit. Figure 7 | | The edges of the tire are rounded off using a 1/8”radius router bit. Figure 7 |
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| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=472[/IMG]]
| + | http://woodworkerszone.com/wikigallery/d/3644-1/Figure+007.jpg |
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| | '''Hub Drilling Fixture''' | | '''Hub Drilling Fixture''' |
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| | The hub drilling fixture is made from Oak for durability. Size the material to the dimensions in figure 8. | | The hub drilling fixture is made from Oak for durability. Size the material to the dimensions in figure 8. |
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| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=473[/IMG]]
| + | http://woodworkerszone.com/wikigallery/d/3646-1/Figure+008.jpg |
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| | Lay out the centerline and the 22.5 degree angle, transfer the line to the edge of the material and center punch the locations for the spoke holes and the center of the axle. Figure 9 | | Lay out the centerline and the 22.5 degree angle, transfer the line to the edge of the material and center punch the locations for the spoke holes and the center of the axle. Figure 9 |
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| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=474[/IMG]]
| + | http://woodworkerszone.com/wikigallery/d/3648-1/Figure+009.jpg |
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| | Use a 1” foster bit to drill a 5/8” deep hole. This hole will hold the hub in the proper location for drilling of the spoke holes. Then drill a 1/4” diameter hole through the remaining depth. Figure 10 | | Use a 1” foster bit to drill a 5/8” deep hole. This hole will hold the hub in the proper location for drilling of the spoke holes. Then drill a 1/4” diameter hole through the remaining depth. Figure 10 |
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| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=475[/IMG]]
| + | http://woodworkerszone.com/wikigallery/d/3650-1/Figure+010.jpg |
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| | Drill the 1/8” diameter holes in the edge of the fixture, insuring the hole is in the proper alignment (90 degrees to the axle). Then drill the 22.5 degree 1/8” hole for the stop positioning peg. Figure 8 by changing the height of the spoke guide holes on each side you can create a double spoked wheel. Practice and set up make all the difference during this operation. | | Drill the 1/8” diameter holes in the edge of the fixture, insuring the hole is in the proper alignment (90 degrees to the axle). Then drill the 22.5 degree 1/8” hole for the stop positioning peg. Figure 8 by changing the height of the spoke guide holes on each side you can create a double spoked wheel. Practice and set up make all the difference during this operation. |
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| | Prepare the hub by routing the ends to a 1/8” radius. Insert a 1/4-20 x 1 1/2" long bolt through the bottom of the fixture, slide the hub onto the bolt and secure with a flat washer and a 1/4-20 wing nut. Figure 11 | | Prepare the hub by routing the ends to a 1/8” radius. Insert a 1/4-20 x 1 1/2" long bolt through the bottom of the fixture, slide the hub onto the bolt and secure with a flat washer and a 1/4-20 wing nut. Figure 11 |
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| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=476[/IMG]]
| + | http://woodworkerszone.com/wikigallery/d/3654-1/Figure+011_001.jpg |
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| | Make a positioning peg sharpened at one end, from 1/8” dowel material. | | Make a positioning peg sharpened at one end, from 1/8” dowel material. |
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| | In figure 12 the 1/8” dowels have been inserted. Trim to size as you fit the hub and spoke assembly into the tire and rim. Insure the axle is centered in the tire. Use thick CA glue to secure the spokes in position. Wick thin CA glue into the spoke and hub attachment point. | | In figure 12 the 1/8” dowels have been inserted. Trim to size as you fit the hub and spoke assembly into the tire and rim. Insure the axle is centered in the tire. Use thick CA glue to secure the spokes in position. Wick thin CA glue into the spoke and hub attachment point. |
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| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=477[/IMG]]
| + | http://woodworkerszone.com/wikigallery/d/3656-1/Figure+012.jpg |
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| | Figure 13 is the size of the hub. | | Figure 13 is the size of the hub. |
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| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=478[/IMG]]
| + | http://woodworkerszone.com/wikigallery/d/3658-1/figure+013.jpg |
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| | You now have a spoked wheel ready for finishing and mounting on the toy. | | You now have a spoked wheel ready for finishing and mounting on the toy. |
| - | [[IMG]http://woodworkerszone.com/igits/picture.php?albumid=42&pictureid=479[/IMG]]
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| | + | http://woodworkerszone.com/wikigallery/d/3662-2/Wheel+Demo+set.JPG |
Select the material, a hard wood like birch, walnut or oak are best for wheels. use pine for set up and testing.
Use a 3” hole saw with a 1/4” pilot drill, and drill 1/2 the depth of the material. Flip the material over and drill the remaining depth. This avoids tear out of the material as the hole saw penetrates the opposite side.
The inside diameter of the hole saw will become the outside diameter of the wheel, Leaving you a 1/2” x 2 7/8” diameter blank. Drill with 1 3/4" hole saw 3/8” deep to form the inside of the tire rim. Leave 1/8” of material in the bottom to form the lip the spokes will rest on. Use a mini lathe to shape the tire and rim, depicted in Figure 3.
In figure 5 flip the blank and use a 1 1/8” hole saw to remove the hub from the center section. The inside diameter of the hole saw is 1” in diameter and becomes the hub.
Figure 6 has the hub removed showing the lip in it’s final form, 1/8” thick 1/8" wide.
The edges of the tire are rounded off using a 1/8”radius router bit. Figure 7
The hub drilling fixture is made from Oak for durability. Size the material to the dimensions in figure 8.
Lay out the centerline and the 22.5 degree angle, transfer the line to the edge of the material and center punch the locations for the spoke holes and the center of the axle. Figure 9
Use a 1” foster bit to drill a 5/8” deep hole. This hole will hold the hub in the proper location for drilling of the spoke holes. Then drill a 1/4” diameter hole through the remaining depth. Figure 10
Drill the 1/8” diameter holes in the edge of the fixture, insuring the hole is in the proper alignment (90 degrees to the axle). Then drill the 22.5 degree 1/8” hole for the stop positioning peg. Figure 8 by changing the height of the spoke guide holes on each side you can create a double spoked wheel. Practice and set up make all the difference during this operation.
Prepare the hub by routing the ends to a 1/8” radius. Insert a 1/4-20 x 1 1/2" long bolt through the bottom of the fixture, slide the hub onto the bolt and secure with a flat washer and a 1/4-20 wing nut. Figure 11
Make a positioning peg sharpened at one end, from 1/8” dowel material.
Mount the fixture in a vise and drill the centerline hole with a drill press.
Loosen the wing nut and rotate the hub until the drilled hole lines up with the positioning peg and insert the peg. Drill the next spoke hole and follow the same procedure until all the spoke holes are drilled.
In figure 12 the 1/8” dowels have been inserted. Trim to size as you fit the hub and spoke assembly into the tire and rim. Insure the axle is centered in the tire. Use thick CA glue to secure the spokes in position. Wick thin CA glue into the spoke and hub attachment point.
