Since getting power steering, I've thought about making a smaller 15" version of my current wheel. I spent some time today tackling this and have a 3d printed mockup ready in place. It's not a perfect model yet. Spokes feel a bit thin. Bit the idea is there and it's easy to update in CAD.
Starting this thread to track my progress.
Mocked up in the cab.
Size comparison to OEM wheel.
The same amount of dish as old wheel
Now comes the fun part. Figuring out how to make it for real. I have a few options.
1: Full CNC Aluminum 6061 Wheel.
This is the simplest option really. My fear with this direction is how do I deal with the wheel getting hot/cold with the temperature? Not sure coatings will help here. Paint/Cerakote can only do so much. Also, will an aluminum spline hold up? I want to guess it will but not 100% sure as the current one is steel.
2. CNC Aluminum Wheel with Steel insert.
Same as above but use a Grant 4579 33 spline adapter ( or custom steel hub insert). This gets rid of my fear of the spline holding up), but doesn't tackle much about the temperature issues.
3. CNC Steel Core with Cast Outer.
Essentially recreating how the current wheel is made. I'd mill a steel core. Most likely weld up a ring and spokes to it and then cast the shape around it. This would require me to have a full CNC pattern, make a two-part mold, make a steel core, and cast. By far the most involved process, but would get me a wheel that isn't temperature sensitive and is strong. Plus can make a few of them if something does go wrong easily.
4. CNC Steel Core with 3D Printed outer shell.
A bit simpler but less repeatable. Mill a Steel core and then skin it with 3d print. Most likely high-quality SLS/SLA based print (not home-based FDM for heat resistance). Then bodywork for seams and paint. Not as intensive as the cast option but maybe not as durable.
Input of these options?
Starting this thread to track my progress.
Mocked up in the cab.
Size comparison to OEM wheel.
The same amount of dish as old wheel
Now comes the fun part. Figuring out how to make it for real. I have a few options.
1: Full CNC Aluminum 6061 Wheel.
This is the simplest option really. My fear with this direction is how do I deal with the wheel getting hot/cold with the temperature? Not sure coatings will help here. Paint/Cerakote can only do so much. Also, will an aluminum spline hold up? I want to guess it will but not 100% sure as the current one is steel.
2. CNC Aluminum Wheel with Steel insert.
Same as above but use a Grant 4579 33 spline adapter ( or custom steel hub insert). This gets rid of my fear of the spline holding up), but doesn't tackle much about the temperature issues.
3. CNC Steel Core with Cast Outer.
Essentially recreating how the current wheel is made. I'd mill a steel core. Most likely weld up a ring and spokes to it and then cast the shape around it. This would require me to have a full CNC pattern, make a two-part mold, make a steel core, and cast. By far the most involved process, but would get me a wheel that isn't temperature sensitive and is strong. Plus can make a few of them if something does go wrong easily.
4. CNC Steel Core with 3D Printed outer shell.
A bit simpler but less repeatable. Mill a Steel core and then skin it with 3d print. Most likely high-quality SLS/SLA based print (not home-based FDM for heat resistance). Then bodywork for seams and paint. Not as intensive as the cast option but maybe not as durable.
Input of these options?
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