Tutorial: Making Wire Wheels

[Ettore]

http://www.esnips.com/doc/5efc9525-9bc8-4242-b6b6-f3904d349236/DSCN6557
This is a tutorial about how to make wire wheels for your model. I will outline the important points, not going into great detail, to give you a guide to use in your building efforts. It is necessary that you have a miniature lathe for this method. I have a Taig lathe and recommend it.

If you cannot see the photos in this thread, please follow the tutorial in the ACME Fotki album:

Wire Wheel Tutorial by Pico Elgin (http://public.fotki.com/ACME-IPMS/tutorial-making-wir/)

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=121&d=1243204955

[Ettore]

1. Wire wheel Photos and Drawing
Wire wheels come in many different sizes and spoke patterns. Take photos of the wheel from many angles from straight on to 90 degrees form the wheel, to see how far out the hub extends beyond the rim. Using the dimensions of the model tire, make a cross section drawing of the tire, wheel, and hub. Dimensions of the rim thickness and diameter of the hub can be determined by their size in the photo.http://www.esnips.com/doc/7314616e-0ef7-4b1b-9803-1831b0bf0308/wire-wheel-1

[Ettore]

Cross section drawing of wire wheel.

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=124&d=1243208029

[Ettore]

2. Materials
The materials I use are PVC water pipe or connectors for the rim. The hub is styrene or, if it is a small diameter and needs strength, aluminum. Spokes are .06" to .09" monofilament nylon fly fishing line from Orvis.

[Ettore]

3. Hub and Rim Construction
From the drawing you know the dimensions of the hub and rim. Turn the rim to size, cut a thin groove on the outside to allow the nylon line to run in.http://www.esnips.com/doc/649400ad-f82c-452d-bff7-9df92716616a/DSCN4179
Turn the hub and cut slots for the spokes with a thin cutting bit. You will need to drill a 3/32" hole for the rod to project from the back of the hub to hold the hub into the stringing jig and, after being cut off, to glue the wheel to the model axle.http://www.esnips.com/doc/e24b19b0-dca8-4797-a046-5576210236d5/DSCN4257

[Ettore]

Images of rim and hub construction.

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=122&d=1243207776

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=123&d=1243207819

[Ettore]

4. Making the Drill Jig
I use 1/2" clear acrylic to make this jig. It is necessary to set the jig far enough from the lathe face plate so that the Dremel drill press does not hit the plywood that is bolted to the face plate. I use a piece of 3/4" MDF between the plywood and the acrylic jig. With an intrenal cutter, turn the acrylic until it matches the rim diameter and width. It should snap in - not too loose or too tight. Leave a hump in the center of the jig to help pry out the rim with a small screwdriver.

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=125&d=1243208629

[Ettore]

5. Drilling the Drill Jig
Next you will wrap a piece of tape around the face plate. Where the tape overlaps, cut it, so that it is the same diameter as the faceplate. Let's say that your wheel will have 48 spokes - 2 sets of 24. Draw 25 equally spaced lines on paper. Lay the tape over the lines, one end on line #1, the other end on line #25. Now mark the tape where each line touches it. This gives you 24 equally spaced marks on the tape. The reason you lay the tape on from line #1 to #25 is because both ends of the tape are the exact same spot - you will not be making 25 holes with it, you will make 24.

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=126&d=1243209144

[Ettore]

Drilling the Drill Jig #2
Wrap the tape around the faceplate and make a marker that points to the marks on the tape.

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=127&d=1243209689

[Ettore]

Drilling the Drill Jig #3
To drill the jig I use a Dremel mounted in a drill press. Turn the base around and weight it down. Position the Dremel over the the jig. For drilling use a #80 (.0135") bit. Hold the faceplate steady as you drill through the jig, then turn it to line up with the next mark. Go slow and be careful as small drill bits are fragile and expensive.

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=128&d=1243210067

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=129&d=1243210186

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=130&d=1243210224

[Ettore]

7. Making the stringing jig
Using a piece of 1/4" clear acrylic, bore a hole the diameter of the hub axle and then cut a 1/16" groove for the rim to snap into. Cut away around that groove so you can easily work on the rim, leaving an arm that you epoxy to a stick. That is held in a panavise, an adjustable vise that swivels in all directions.

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=131&d=1243253784

[Ettore]

8. Spoke Stringing Pattern and Technique
Here's a diagram of the spoke stringing pattern. Note that the number of spokes must be divisible by 4. Start at 1, go to 2, which is directly across the rim from 1, go to 3, then to 4. Repeat the pattern.

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=132&d=1243254026

[Ettore]

Spoke Stringing Pattern and Technique #2
Most spokes are 1/4" in diameter. In 1/24th scale that is about .010". I use .009" monofilament line, and figure paint adds about .001". Snap the rim into the stringing jig.

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=133&d=1243260820

[Ettore]

Spoke Stringing Pattern and Technique #3
Use a clip to hold the hub axle from the back.

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=134&d=1243260971

[Ettore]

Spoke Stringing Pattern and Technique #4
It may be necessary to shim the hub into proper position in relation to the rim. String inner spokes first, then outer spokes. A touch of CA glue will keep the lines taunt. Remove carefully.

http://www.opentrackaction.com/acmeforum/attachment.php?attachmentid=135&d=1243261242

[BRE350Z]

Pico:

Thanks for taking the time to prepare and post this information as well as on the Fotki site.

Wayne