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Ok, this may seem intuitive to some, but I’d like to ask the populous how they go about cutting down plastic wheels to make inserts... procedures, tools, etc. I’ve done it... didn’t much care for how I went about it, and wasn’t completely satisfied with the results.

Val

If I recall Harry did an article on this somewhere not too long ago. I have a homemade truer that works the same way as a Razor. I run it in reverse and use a really sharp wood chisel to take the ridge off and then slowly sand down until it fits in the hub and then while its spinning cut off as much as I need with a utility/box-cutter knife or razor saw.

For years, I used a Harbor Freight mini belt sander to great effect. I have used a drill with a sanding board, a Dremel on low rpm, etc.

These days, I use a rig I made for my lathe which is much faster and very precise. I generally use a lathe tool for the rib, and a 100 grit sanding board to get the diameter correct. The disk can then be very precisely cut with a parting tool or a hand held razor saw.

I use a drill press and assorted tools. Check the attached PDF file for instructions.

Peter

The big question is how do hold the insert in your drill or whatever. I have glued round plastic to the back side and put it in a drill, turned is slowly while holding it against my belt sander. This works fine until the glue bond breaks.

There's a unique method invented by our member DDyke in which a cheap Harbor Freight oscillating drum sander is used while the car is hooked up to power (turning in opposition). In no time at all, you have two plastic wheels the right diameter to slice off and glue into aluminum wheels.

Just wanted to thank you guys that responded to this post. I got some good ideas ... and that was just what I was fishing for!

Val