Dan Dubeau
Ultra Member
I am. Almost everything I own that rides on cheap rubber/plastic tires is broken. I finally had enough, and decided to do something about it....
![1Jh2R52.jpg 1Jh2R52.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57456-5f88ddd96f827079b8e84ca11cac937f.jpg?hash=X4jd2W-CcH)
First step was to buy some steel, as I didn't have anything suitable on hand. Let me just get this out of the way right now, this is not a financially motivated decision, this is one born out of frustration and a desire to end the hassle of perpetually flat and broken tires everytime I need to move something.....I will do the math at the end, just to see the true cost of these though. I went with 3/16"x2" flat for the rim, and 3/16"x1.5" for the spokes. I bored some 1/2" pipe out a bit to fit the 5/8" axles.
Next step was to send them through the roller. Was really hoping that this duct roller would be up to the task. I've rolled 1/8"x2" before so I was hopeful. It did, but was a work out, and I don't think it was happy...... None of my drills or impacts would spin it, so it was all by hand with a 24" breaker bar. Wasn't really too bad though, and went pretty quick. I think it was 12 trips through the rollers. I guesstimated on having to burn about 4" on each end that I'd have to chop, but that was too much. Next ones I will only leave about 4" total for waste.
![xSD5N6w.jpg xSD5N6w.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57468-186e075cf653142f0e05b14b6f99f19f.jpg?hash=GG4HXPZTFC)
Printed some radius gauges onto some cardstock for 8, 10 and 12" wheels.
![3IGbQ61.jpg 3IGbQ61.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57458-cca99199b70e0c2336eb4225161fb2c4.jpg?hash=zKmRmbcODC)
I cannot get this roller to roll straight. I spend a good deal of time trying to align the rolls, and the steel, etc, but I think there's just too much flex and slop in it from being pushed beyond it's design purpose that it's just something I'll have to deal with. Hopefully I can straighten them out....
I then cut off a bit from one end, and measured the circumference needed. Went with a nice round 31.5" on these instead of 31.4, but should be close enough......
![cRptRrz.jpg cRptRrz.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57461-3aa9a40e2576340f77338cd1e863316d.jpg?hash=OqmkDiV2NA)
![U5Licdi.jpg U5Licdi.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57466-6680982a8a357a5f4c39d1a4377d0a23.jpg?hash=ZoCYKoo1el)
Chopped them to length, and manipulated them in a vise to close them up and align the ends. I used a ratchet strap to close them up for tacking, and a kant twist on the seam for alignment. With some twisting and persuading they lined right up pretty easily.
![cjmFBQc.jpg cjmFBQc.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57460-939f11e8bd91a708140e38fb5de6b336.jpg?hash=k58R6L2Rpw)
![fyj4xpu.jpg fyj4xpu.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57462-dcb20f7168502aa4447f72814b808333.jpg?hash=3LIPcWhQKq)
![1uVIc3T.jpg 1uVIc3T.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57457-bef89d70762d8587cf0eb446eaf82dd4.jpg?hash=vvidcHYthY)
I tacked up the inside, removed the clamps and strap then welded the inside completely. Then I ran a cutting disc down the outside groove, so I could weld that up with some better penetration.
![sE2Pdqb.jpg sE2Pdqb.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57465-8d4c4a73d8e489a7d8a134e513844fc9.jpg?hash=jUxKc9jkia)
![Bw8khk4.jpg Bw8khk4.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57459-aa76dc3d4ede83375672caddb260c1c4.jpg?hash=qnbcPU7egz)
![S61GJEq.jpg S61GJEq.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57464-985e1e0c802f6cc2d7d935772435d943.jpg?hash=mF4eDIAvbM)
I also chopped up some hubs, and bored them out while they were cooling. Then ground them all smooth.
![jIiPXuV.jpg jIiPXuV.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57463-cc021ed4b4cdb912e6fcdc37510833f8.jpg?hash=zAIe1LTNuR)
Next step is to fill in the blanks......
![1Jh2R52.jpg 1Jh2R52.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57456-5f88ddd96f827079b8e84ca11cac937f.jpg?hash=X4jd2W-CcH)
First step was to buy some steel, as I didn't have anything suitable on hand. Let me just get this out of the way right now, this is not a financially motivated decision, this is one born out of frustration and a desire to end the hassle of perpetually flat and broken tires everytime I need to move something.....I will do the math at the end, just to see the true cost of these though. I went with 3/16"x2" flat for the rim, and 3/16"x1.5" for the spokes. I bored some 1/2" pipe out a bit to fit the 5/8" axles.
Next step was to send them through the roller. Was really hoping that this duct roller would be up to the task. I've rolled 1/8"x2" before so I was hopeful. It did, but was a work out, and I don't think it was happy...... None of my drills or impacts would spin it, so it was all by hand with a 24" breaker bar. Wasn't really too bad though, and went pretty quick. I think it was 12 trips through the rollers. I guesstimated on having to burn about 4" on each end that I'd have to chop, but that was too much. Next ones I will only leave about 4" total for waste.
![xSD5N6w.jpg xSD5N6w.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57468-186e075cf653142f0e05b14b6f99f19f.jpg?hash=GG4HXPZTFC)
Printed some radius gauges onto some cardstock for 8, 10 and 12" wheels.
![3IGbQ61.jpg 3IGbQ61.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57458-cca99199b70e0c2336eb4225161fb2c4.jpg?hash=zKmRmbcODC)
I cannot get this roller to roll straight. I spend a good deal of time trying to align the rolls, and the steel, etc, but I think there's just too much flex and slop in it from being pushed beyond it's design purpose that it's just something I'll have to deal with. Hopefully I can straighten them out....
I then cut off a bit from one end, and measured the circumference needed. Went with a nice round 31.5" on these instead of 31.4, but should be close enough......
![cRptRrz.jpg cRptRrz.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57461-3aa9a40e2576340f77338cd1e863316d.jpg?hash=OqmkDiV2NA)
![U5Licdi.jpg U5Licdi.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57466-6680982a8a357a5f4c39d1a4377d0a23.jpg?hash=ZoCYKoo1el)
Chopped them to length, and manipulated them in a vise to close them up and align the ends. I used a ratchet strap to close them up for tacking, and a kant twist on the seam for alignment. With some twisting and persuading they lined right up pretty easily.
![cjmFBQc.jpg cjmFBQc.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57460-939f11e8bd91a708140e38fb5de6b336.jpg?hash=k58R6L2Rpw)
![fyj4xpu.jpg fyj4xpu.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57462-dcb20f7168502aa4447f72814b808333.jpg?hash=3LIPcWhQKq)
![1uVIc3T.jpg 1uVIc3T.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57457-bef89d70762d8587cf0eb446eaf82dd4.jpg?hash=vvidcHYthY)
I tacked up the inside, removed the clamps and strap then welded the inside completely. Then I ran a cutting disc down the outside groove, so I could weld that up with some better penetration.
![sE2Pdqb.jpg sE2Pdqb.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57465-8d4c4a73d8e489a7d8a134e513844fc9.jpg?hash=jUxKc9jkia)
![Bw8khk4.jpg Bw8khk4.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57459-aa76dc3d4ede83375672caddb260c1c4.jpg?hash=qnbcPU7egz)
![S61GJEq.jpg S61GJEq.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57464-985e1e0c802f6cc2d7d935772435d943.jpg?hash=mF4eDIAvbM)
I also chopped up some hubs, and bored them out while they were cooling. Then ground them all smooth.
![jIiPXuV.jpg jIiPXuV.jpg](https://canadianhobbymetalworkers.com/data/attachments/57/57463-cc021ed4b4cdb912e6fcdc37510833f8.jpg?hash=zAIe1LTNuR)
Next step is to fill in the blanks......