fal308 wrote:Very nice
Did you steam it to get to shape?
fal308: Thanks. Bent lamination with steam assist is certainly the conventional way of making wooden wheels - in fact the Nardi wheel on my Cat is made that way.
But if you look closely at the fake grain pattern on these plastic e-body wheels, you will note that they are designed to look like they are constructed of multiple pieces of walnut, finger-jointed together.
To make the wheel, we finger-jointed six pieces of walnut into a hexagon shape, then trimmed the hexagon into an inch-wide donut about 16 inches in diameter. We made two of these donuts, then using a mortising bit, formed a groove in both for the steel core of the wheel. We then sandwitched the steel core between the two donuts using urethane glue. From there, it's a matter of replicating the exact contour of the original wheel using roundover bits - and then a spindle sander to form the grips on the backside.
Chrysler must have made a real wooden mock-up to design these plastic wheels, because the fake grain pattern is really quite tastefully done and does represent proper grain orientation.