Making steel wheels for my TIG cart

[frieed]

Cart build is here https://www.rme4x4.com/threads/building-a-tig-cart.114259/


So after trying a couple purchased wheels I decided to make my own from 3/16" x 1" flat strap.

First stop, cut 10 pieces for the spokes, 5 each wheel:



Then I tested to see if my 6" hole saw was up to the task (it was not)


Alternate method. Weld them all together and do all shaping with them as a solid unit
Clamped up ready to tack weld


All welded up with 6011 stick


Now that they are one, time to even out the edges


Now time to drill the 1/2" axle hole


Ready to be separated


A little time with a zip wheel and presto


With a 1/2" tube to keep the holes aligned I spread the spokes out and tacked them

 

[frieed]

finally, I used my HF ring roller to make the rim

 

[Shawn]

That is killer, good idea!

Thanks for sharing

 

[TRD270]

Some beefy wheels, you making rail road track next to run them back and forth on?

 

[frieed]

Here is how I make the rims.
The metal will bend about the center line as you roll it out so the length of the flat stock is determined by the diameter of the wheel at the center of the rim thickness. In my case, 7-5/8" so 7.625 * pi = 23.95".. call it 24.

rolling that puppy out with the super cheezy HF ring roller
Note to Self: next time mount the ring roller to the table that's not on wheels. Chased that thing all over the garage


keep rolling tighter until the ends meet. Line them up the best you can and tack together


verify the spokes fit, finish the weld, then grind flush.
Because of how the ring roller works, the last inch or so of the bar ends aren't curved.
Since the ring is now continuous, I put it back into the roller to smooth out the flat spot made by the two ends at the weld.


Next weld the spokes in and paint.
The final result


The axles are 1/2 x 3" bolts welded to frame.
These wheels are narrower than my original wheels and the bolt shoulder extends 3/4" past the wheel hub.
I need to get a 1/2-13 die to cut threads, reducing the size of the shoulder, and then trim the length of the bolt

 

[Herzog]

Well done!

 

[Kevin B.]

Eric, that's freaking rad.

 

[dutchman]

Eric, that's freaking rad.

Agreed!!!

 

[Greg]

That's amazing, Eric!

 

[bryson]

The axles are 1/2 x 3" bolts welded to frame.
These wheels are narrower than my original wheels and the bolt shoulder extends 3/4" past the wheel hub.
I need to get a 1/2-13 die to cut threads, reducing the size of the shoulder, and then trim the length of the bolt

What about just using a piece of tube as a spacer on the axle to push the wheels out wider?

 

[frieed]

My issue with the previous wheels was how far out the axle protruded. I'm looking forward to tucking the axles in much closer.