Thread: Gatto's VW Beetle... Extremely slow W.I.P.

Made a crude start on my wheels this past week. Found out my drill press isn't quite square to start with. But I tried to persevere, and drilled 4 outer tyre sections, followed by the inner wheel rims. Then it all went pear shaped. I tried sanding the inner wheels on a cut down bolt, but they were getting out of round. I got three of them pressed together, and was "gently" tapping the fourth, when it split the outer tyre!!!

So... back to square one.

Glad to see your back on it yonnee

Originally Posted by Yonnee

Made a crude start on my wheels this past week. Found out my drill press isn't quite square to start with. But I tried to persevere, and drilled 4 outer tyre sections, followed by the inner wheel rims. Then it all went pear shaped. I tried sanding the inner wheels on a cut down bolt, but they were getting out of round. I got three of them pressed together, and was "gently" tapping the fourth, when it split the outer tyre!!!

So... back to square one.

Wheels!

That's what I have the most trouble with, as do many others.

When you say you were sanding on a cut down bolt, I assume you meant sanding on the drill press, using the bolt as a shank. I can't get that to work either. The softer long-grain side gets sanded much more quickly than the end-grain.

A better method is to make a jig for sanding circles on the disc sander, very similar to a bandsaw circle-cutting jig. ie. A bolt or similar for a pivot .....
This is getting complex - it'll be clearest if I draw it:

Circle Sanding Jig.JPG


I've done similar using a Dremel w/ router table and a sanding drum or straight router bit. The router bit method is dicey.

Edit: Putting a very slight taper on the inside of the tyre and outside of the rim makes it easier to assemble them. I 'creep up' on the size, so the rim and tyre are flush on the outside once the taper is seated.
Only a few thou of taper is needed.

Here is a simple one I made for my OSS.



I put a knob on mine to lock it in once you get to the desired diameter.


Bret

Originally Posted by bobman 58

Glad to see your back on it yonnee

Thanks Bobman, time is getting away from me again!!

Originally Posted by Hermit

Wheels!

That's what I have the most trouble with, as do many others.

When you say you were sanding on a cut down bolt, I assume you meant sanding on the drill press, using the bolt as a shank.

Yep!

I can't get that to work either. The softer long-grain side gets sanded much more quickly than the end-grain.

BINGO..!!
I think that's what was happening to me. Until now, I couldn't figure out why the centres seem to be getting out of round when trial fitting them into the outer tyres, but now it makes sense...

A better method is to make a jig for sanding circles on the disc sander, very similar to a bandsaw circle-cutting jig. ie. A bolt or similar for a pivot .....
This is getting complex - it'll be clearest if I draw it:

Circle Sanding Jig.JPG


I've done similar using a Dremel w/ router table and a sanding drum or straight router bit. The router bit method is dicey.

Edit: Putting a very slight taper on the inside of the tyre and outside of the rim makes it easier to assemble them. I 'creep up' on the size, so the rim and tyre are flush on the outside once the taper is seated.
Only a few thou of taper is needed.

Hmm... might have to have a play around.
I have thought of possibly a cheats way... 30mm and 35mm Tassie Oak dowel from Bunnings. If either of them are a tight fit/neat fit into the hole that my 30mm & 35mm forstner bits drill, then I'm part way there. And a 1.8M length will get me a HEAP of wheel centres!!

Originally Posted by Yonnee

I have thought of possibly a cheats way... 30mm and 35mm Tassie Oak dowel from Bunnings. If either of them are a tight fit/neat fit into the hole that my 30mm & 35mm forstner bits drill, then I'm part way there. And a 1.8M length will get me a HEAP of wheel centres!!

You could make a fleet of Beetles with 1.8m. (Or is it a herd?)

If you do try this, I'll be interested to hear how it fits. If all else fails, I'll do the same with mine. I'll try on the lathe first, though. (When it eventually gets here - still waiting. Probably tomorrow.)
I lay awake pretty late last night, beginning to plan the wheels in my head. In a way, they're harder than spoked wheels.

LMAO...
A colony of vw's....

Maybe not Beetles, but I'm thinking if it works OK, then a Prime Mover and Trailer might be on the cards. I bought 100 wooden golf tees, so I have plenty of air horns... LOL.

Using what you have how about putting a drum sander (you could make your own drum) into your drill press then make a jig like Bret's(piece of wood represents this in my photo). That way you are using a machine what you already have.

DSCF2319.jpg

This is my drill press the box below complete with different size inserts, the vac takes all the dust away if I want to drill I put a sacrificial piece of wood on top. With this design you can raise the table so you can use the full height of the sander.

DSCF0043.jpg

That's a pretty nice drill press table Derek.

Thanks guys it does get used a lot well worth the time and effort to build. Anyway back to your wheels Yonnee have you now managed to get them round.

Originally Posted by Dalboy

Thanks guys it does get used a lot well worth the time and effort to build. Anyway back to your wheels Yonnee have you now managed to get them round.

Originally Posted by Dalboy

Nope...
Tonight, on the way home from work I'll drop passed Bunnings (similar to your Homebase or Wickes) and grab some 30mm dowel and see how that goes.

Back to square one... Again!!

The Tassie Oak dowels that Bunnings sell as "30mm", are actually 28.6mm.

Have to have a re-think.

Originally Posted by Yonnee

Back to square one... Again!!

The Tassie Oak dowels that Bunnings sell as "30mm", are actually 28.6mm.

Have to have a re-think.

I'm having bad dropout problems at the moment, (thanks Telstra), but I'll try to get through this.

Another method - I know you have a Dremel, but do you also happen to have a router table attachment to go with it?

I did the rims and tyres for the Ford Roadster like this, to help keep them from going out-of-round:

am. Rim Outside Jig.JPG al. Rim Inside Jig.JPG