Rays89
My computer never gets turned on over the weekend, too many things to do. So, I just saw your question this morning.
I have tried a number of ways to make wheels, so far, none have been completely satisfactory. Smaller wheels, such as in my picture are a bit more of a problem than larger ones. Larger ones can be cut out with a router and circle cutter rig, or with a roto tool--or even roughly cut out with a saber saw and sanded round on a belt sander.
The wheels in the picture were made with a circle cutter on a drill press. I alternate cutting the inner and outer diameters until almost cut through (cutting from both sides of the board also alternately). The outer diameter is cut through first then the wheel is secured and the inner diameter cut finished. Kind of awkward---but it works!!
On soft woods like pine or poplar, I reverse the cutter bit in its' holder, which doesn't leave the beveled edge on the outer diameter of the wheel (circle cutters are designed to cut holes, not circular disks!!). With oak, which was used on the one pictured, the reversed cutter really isn't my choice (I have done it a few times, but it ruins a cutter rather quickly). Instead, the wheels are chucked in my lathe and the bevel is removed with a lathe cutter.
Sometimes I have cut out the outer diameter, place the wheel blanks on a threaded shaft through the cutter pilot hole, chuck them in the lathe and cut the bevel from them at the same time---makes all of them the exact same diameter.
The spokes are plain old 1/4" dowel, and the hub is cut from plain old 1" dowel. Hopefully some of the others on the forum will list things they do, which may give both you and I some new ideas and tricks. How 'bout it, those of you who are woodworking masters---what are your tricks???
