ExSpurt’s wheels are simple and easy to make. All you need is a lathe! I can turn out eight wheels in one very relaxing evening and I an a beginner with machine tools. Start with a 1” diameter 7075 aluminum rod with about 2” protruding from a three jaw chuck. Turn the OD down to .700”, finish cut the end, and drill a 3mm hole down the middle for the axle. Cut off about an inch of turned material. Repeat the process seven more times.
Mount a 5/8 inch end mill in a tool holder on the carriage and bore out the insides of each wheel such that there is .250” left for the hub area. The hole in the wheel actually comes out to about .605” diameter. Then finish cut the end so that the wheel is .950” long.
Drill and tap a 4-40 threaded hole for the axle set screw. Clean up the 3mm axle hole, the 4-40 thread, and install 4-40 set screw. One important step is to scratch two lines on the wheel’s outer face to locate the set screws. There, eight new wheels in one evening. |