This file is underconstruction.... there will be additiional editing and photos added when possible...

.... very suitable for small  lightweight models ...   where weight and cost is an important consideration.



Click on any photo for a closer view....

In this example we will take a 2 inch / 50 mm Dave Brown light wheel and make 2 separate lighter,  thinner,  ones....   You can use this procedure for most any of the Dave Brown  (square, flat tread)  wheels.    I should mention that the center ply disk will dictate the usability of the wheel in regard to the weight of the model.   The smaller the disk relative to the overall wheel size,  the more flexible and soft the tire will be.    The larger the disk, the "harder" the tire with less sideways rollover and flexing.     I would recommend that the diameter of the disk be no less than 2/3 rds the size of the wheel diameter.   The disks on the wheels shown here on the demonstration set are actually a bit too small.










First we take the original wheel and slowly / carefully 'slice' it down the center with a bandsaw.    Do NOT hold the wheel with your hands.... use a clamp that will hold the hub securely.







   For each individual wheel cut two 1/64 ply disks ( wheels for models of less than 12 ounces) ,   or 1/32 ply (for models of over 12 ounces),  a 3/16" length of 1/4" hardwood dowel  (hub) ,  and a brass tube axle sleeve of suitable diameter for your axle.    An aluminum tube sleeve and / or a smaller dowel can be used for the smaller wheels if desired.   In this example I used a 3/64" inside diameter tube,  3/8" long.






After drilling the ply disks and the dowel hub for the brass axle sleeve,   apply epoxy to the dowel hub  and insert in the center of the foam wheel .   Then apply epoxy to the inside of the disks and place them on the sides of the foam ,  carefully centering on the axle hole.  Use a wire to keep them in aligment.     Clamp securely and allow to cure/dry.    If you did not choose to glue / insert the sleeve during the assembly process, now you can carefully drill the wheel for the brass axle sleeve at this time.    Epoxy the sleeve in place, using a wire to insure a straight alignment.


Jim Baxter, October 2000, updated:  01-17-01