First paying job! Need suggestions...

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... okay, so it's no biggie. A fellow I work with is building a firetruck as an envelope holder for a neighbor firefighter who's getting married in May and asked if I could make four wheels for him.
1&1/8 thick by 4&1/4 diameter. Going to be painted. I'm thinking to glue some 3/4 and 3/8 MDF together to get the thickness, rough them out on the band saw, clean them up with a template taped to them on the router table. No biggie.
But he wants the outside to show a hub, which means routing out a ring inside each wheel. I was thinking I'd drill two holes in the router base in the table for a pin and use a straght bit, but starting the cut seems to me a rather dangerous idea.
Is there a safe way to do that? The other option (safer) is to build a jig and use the plunge router, rotating the wheel under the bit. The whole job is only worth $40, but it's a learning experience so I don't really care about the money. OTOH, that's not much budget to justify buying a new tool.
The other option would be to turn them on the lathe... but my turning skills aren't such that I'm confident in being even close to duplicating the other three. Again, it would be a learning/practice experience.
Suggestions from the gallery are most welcome.
djb
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On Tue, 02 Mar 2004 19:26:46 -0600, Dave Balderstone

You could drill a large hole with a forstner bit, or rough out the hole with a jig or scroll saw. With MDF, I'd probably just drill a big hole and start there. You could make one by hand and use a pattern bit and carpet tape to make the others.
That fire truck sure would look nice made of ash, maple, or birch and stained with red Solar Klux. <G>
Barry
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On Wed, 03 Mar 2004 01:36:10 GMT, B a r r y

Damn spell checker!
That's SOLAR LUX!
Barry
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I'm not sure I follow... Maybe my description was lousy.
He wants the effect of a tire mounted on a rim, with a hub in the center, but we're not talking spokes. They'll be solid disks.
So I was thinking a disk (roughed out then cut with a pattern bit in the router), then routing a depression about 3/4" wide, in about 1/2" from the outside diameter, leaving central hub 1 & 3/4".
djb
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Then there's the 'reverse psychology' approach -- make a flat disk for the core wheel. drill a _big_ hole with a Forstner bit, in the center of it. (this gives you the 'rim' round the wheel. Now, drill a medium-size hole in the center of the big one. stick a chunk of dowel in *that* hole. cut it off proud of the disk.
Voila! raised tire/rim, with a protruding 'hub'.
To get really fancy, use a "rosette cutter", instead of the forstner bit.
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On Tue, 02 Mar 2004 19:59:46 -0600, Dave Balderstone

That would be how I would do it as well.
Barry
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Dave Balderstone wrote:

Start with a square piece of wood. Use a Forstner to hollow out the "hub" area. Using the center thus marked, cut the outside with a hole saw or fly cutter. Glue a dowel stub into the hole to produce the "hub." If you want the rim rounded over, maybe a roundover and router, but you could probably just as easily chuck a wheel in your drill press or lathe and round it with rasps/sandpaper/etc.
Or cheat and buy some ready-made wheels online. ;)
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He tried. Can't find the diameter he needs in Canada.
djb
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Can he buy them in inches and turn them down on a lathe that does metric diameters? Ed
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Apparently not. 4-1/4" is what he needs and they don't seem to be readily available at that size or larger.
I think we've got a workable plan now, though... and I have an excuse to buy a couple of big forstner bits. ;-)
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Is that the stain with the pointed white hood?
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It's the one that can't get along with the stains of other colors. <G>
Barry
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B a r r y wrote:

Or stains manufactured in Israel.
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Use a rosette cutter in the drill press and then use the center point as a guide to cut out circles on a band saw. Then bullnose the outside edge. Or just go and buy some corner blocks that are pre done and glue them together and then cut them out the same.

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I don't have a circle cutter but maybe that's the tool I buy. I was planning on bullnosing the outside, but it's routing out the ring around the hub that I'm trying to figure out.
djb
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Here are a couple of links for you please take a look . Like they say a picture is worth a thosand words. Hopefully I could be of some help.
http://www.mlcswoodworking.com/shopsite_sc/store/html/smarthtml/pages/rosette.htm
http://www.right-tool.com/romcar218ros.html
wrote:

a
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I didn't even know such things existed...
Mind you, at $60 US that's a lot more than the $40 CAD I'd get for the job, but I'll check some local shops and see what's available.
Thanks!
djb
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You can go to your local Hardware store IE Home depot ,Rona or lumberland and just buy the corner blocks that are pre cut with the rosette centers and then cut them in to circles instead of squares to make wheels this might be the cheapest way of obtaining what you need with out having to buy any tools.
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http://www.mlcswoodworking.com/shopsite_sc/store/html/smarthtml/pages/rosette .
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Good thought. I'll czech it out tomorrow.
djb
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Many of the back issues of both Wood & Woodsmith have had articles on various toy truck/road building machines. (see: Fat Cats series in WOOD mag) They also showed many ways of creating different wheels. Might be worth a little research in some of these old issues.
DexAZ
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