TheKid
02-07-2008, 04:37 PM
I condensed 3 pages of this important subject. Hopefully, I left nothing important out:
Hub Washer Sources: http://www.aircraftspruce.com/catalog/hapages/an970flatwashers.php
http://www.mcmaster.com/
Cadmium Warning: http://www.osha.gov/SLTC/cadmium/
Just bought some 2.5" washers from Brofasco. Careful attention to making a template and using a hole punch is essential. Also a great tool to have is a center drill. These allow you to make accurate starter holes. By using a center drill first, the drill bit will not run away on you as can happen even with using a hole punch. Center drill can be bought for a few dollars at any supplier handling machine tools and is worth its weight in gold.
Here is a link to a pair of washers I used to make hubs:
http://images.andale.com/f2/115/123/10264406/2006/10/13/Spoke_Washers2.jpg
It is important to note that even though these washers have a 5/8" hole, it will most likely be a little larger than a 5/8" rod by about a 32nd. Before welding, add a shim to take up the space so the washer sits as close to center as possible. I discovered that if you cut up an aluminum pop can, it is the perfect material for a shim and nicely centers the hub onto the shaft. I'm placing a piece of angle iron clamped into my vise. Since the angle iron is cut straight at the end, butting the washers with axle up to the end ensures when you weld that the washer will be in perfect alighment. Of course I will make a tack weld and check before continuing. Once the tack is done and you are satisfied, remove the shim and finish welding the washer onto the axle.
Great tip, Robert. I went to a machine shop that was closing down (retiring) and bought some center drill bits. The perfect size for making the spoke holes is a #3 center drill. (Richie Rich)
They'll fit in any hand drill or drill press and won't 'drift' like a regular drill bit. Plus, there's a tip on each end in case you break or wear out one end. Another advantage is that you can drill and countersink the holes in one operation. Here's a picture....
http://upload.wikimedia.org/wikipedia/commons/d/df/CenterDrills123456.jpg
When I welded my hubs, I used a piece of angle iron and butted the washer at the end so I had a pefect 90 degrees as well used a welding magnet for extra stability. Even with all this, I still had a significant warping, but by tapping with a hammer, I was able to minimize the warping to a point where it turned very true. I rotated the welded hub along the angle iron and tapped where the highpoints were until I was satisfied the hub ran true. Warping is just a natural reaction to the intense heat created by welding.
I use vasaline for cutting oil - just dip the bit right into the jar. Seems to do the trick.
I made a simple fixture to hold all the washer together and drilled them all at once. Then I used a larger drill bit to chamfer the holes ... now will come the fun part of welding them to the axle.
http://www1.snapfish.com/thumbnailshare/AlbumID=140948414/a=6231239_6231239/t_=6231239
Mike
Originally posted by Bikerbearman
ed k, if you are still around, did you ever get your wheels build using the washers from aircraft spruce? has anyone else used these and how did they work? i couldn't fine anymore post about it except ed had no prob drilling. if these are ok then i will order some. thanks
-JW
The wheels went together really well. I like the fact that the center whole fit so snugly to the shaft that I didn't need to worry about "shimming" to center it. I actually brazed the washers to the hubs. Brazing is a nice method for joining when there's a snug fit like a shaft into a hole. I'm a little reluctant to talk about how well it worked because I haven't finished my DW so I don't have any road miles on my DW yet but I'm pretty confident that the brazing will hold and it looks great. I'd bet the close fit would help if you welded them too. I sizzled the cadmium coating off first with muratic acid. got my washers fri. great turn around. they fit nice, wow, i like em.
Hub Washer Sources: http://www.aircraftspruce.com/catalog/hapages/an970flatwashers.php
http://www.mcmaster.com/
Cadmium Warning: http://www.osha.gov/SLTC/cadmium/
Just bought some 2.5" washers from Brofasco. Careful attention to making a template and using a hole punch is essential. Also a great tool to have is a center drill. These allow you to make accurate starter holes. By using a center drill first, the drill bit will not run away on you as can happen even with using a hole punch. Center drill can be bought for a few dollars at any supplier handling machine tools and is worth its weight in gold.
Here is a link to a pair of washers I used to make hubs:
http://images.andale.com/f2/115/123/10264406/2006/10/13/Spoke_Washers2.jpg
It is important to note that even though these washers have a 5/8" hole, it will most likely be a little larger than a 5/8" rod by about a 32nd. Before welding, add a shim to take up the space so the washer sits as close to center as possible. I discovered that if you cut up an aluminum pop can, it is the perfect material for a shim and nicely centers the hub onto the shaft. I'm placing a piece of angle iron clamped into my vise. Since the angle iron is cut straight at the end, butting the washers with axle up to the end ensures when you weld that the washer will be in perfect alighment. Of course I will make a tack weld and check before continuing. Once the tack is done and you are satisfied, remove the shim and finish welding the washer onto the axle.
Great tip, Robert. I went to a machine shop that was closing down (retiring) and bought some center drill bits. The perfect size for making the spoke holes is a #3 center drill. (Richie Rich)
They'll fit in any hand drill or drill press and won't 'drift' like a regular drill bit. Plus, there's a tip on each end in case you break or wear out one end. Another advantage is that you can drill and countersink the holes in one operation. Here's a picture....
http://upload.wikimedia.org/wikipedia/commons/d/df/CenterDrills123456.jpg
When I welded my hubs, I used a piece of angle iron and butted the washer at the end so I had a pefect 90 degrees as well used a welding magnet for extra stability. Even with all this, I still had a significant warping, but by tapping with a hammer, I was able to minimize the warping to a point where it turned very true. I rotated the welded hub along the angle iron and tapped where the highpoints were until I was satisfied the hub ran true. Warping is just a natural reaction to the intense heat created by welding.
I use vasaline for cutting oil - just dip the bit right into the jar. Seems to do the trick.
I made a simple fixture to hold all the washer together and drilled them all at once. Then I used a larger drill bit to chamfer the holes ... now will come the fun part of welding them to the axle.
http://www1.snapfish.com/thumbnailshare/AlbumID=140948414/a=6231239_6231239/t_=6231239
Mike
Originally posted by Bikerbearman
ed k, if you are still around, did you ever get your wheels build using the washers from aircraft spruce? has anyone else used these and how did they work? i couldn't fine anymore post about it except ed had no prob drilling. if these are ok then i will order some. thanks
-JW
The wheels went together really well. I like the fact that the center whole fit so snugly to the shaft that I didn't need to worry about "shimming" to center it. I actually brazed the washers to the hubs. Brazing is a nice method for joining when there's a snug fit like a shaft into a hole. I'm a little reluctant to talk about how well it worked because I haven't finished my DW so I don't have any road miles on my DW yet but I'm pretty confident that the brazing will hold and it looks great. I'd bet the close fit would help if you welded them too. I sizzled the cadmium coating off first with muratic acid. got my washers fri. great turn around. they fit nice, wow, i like em.