Re: How do i make this part??
 

I order almost all our tooling from KBC Tools. They have a local branch in Hayward you can go to and pick it up. They ship to us for free too, but that may be because we order through the government.

Re: How do i make this part??
 

one more thing you might want to consider:

the width (and diameter) of bicycle hubs isn't determined arbitrarily; the smaller the hub width and/or diameter, the less the wheel will be able to handle side loads (such as those created by sharp or high speed turns). if the hub width/diameter is to small, the spokes will fail, and the wheel will collapse.

Re: How do i make this part??
 

You can make your own lathe cutter with a grinding wheel and a whetstone. You just need some tool steel (3/8" square by 6" is a decent size).

Now, facing the angle is pretty simple IF you have a compound tool holder (I forget the exact name, but it rotates and extends the block that holds the tool). Here's how: Set the rest's lowest rotation to the required angle. There should be a ring showing the degrees. Line up the cutter so that it will cut the whole depth. (You'll also need the right cutter... Right handed and left handed are different and cut differently.) Mark what you want to cut between. Then, you position the slide so that the tool is where it needs to be. Once you start, you only use the long travel to go a little bit at a time. You use the travel on the rest to move the tool across the part.

The tricky part is that this is on the inside, so access and depth determination will be harder. You'll need to stop more often to check depth.

Re: How do i make this part??
 

I'm surprised nobody else has mentioned this yet, but you can purchase those motors and wheels (at least I think they're the same wheels) here already attached together. And if you're worried about the wheels being cantileverd.... don't worry. I've seen some heavy weight combat robots using the same exposed cantileverd wheel system with great success.

Re: How do i make this part??
 

Have you considered a plastic wheel?. You'd still have to make a hub, but it may (or may not) be easier.

Re: How do i make this part??
 

Google ENCO for tools, they sell everything from cheap Chinese to excellent USA/Japanese tools.

You don't need special tooling for the bores, but knowing how to grind a special tool for something is a handy skill; in this case a tool with the cutting tip towards the left side would be fine for the bores.

As EricH wrote, your lathe has three wheels to move the cutting tool: The carriage (towards and away from the headstock), the crossfeed (perpendicular from the axis of the lathe, in other words front to back) and the compound. What EricH means is the compound, which can be adjusted to any angle you need. There are setscrews or screws that hold it in place, and a scale marked in degrees around it. Loosen the screws, move it to the angle you need, and tighten them up again (not TOO tight), then by turning the compound the tool will move at the exact angle you want.

Making a mandrel to hold the workpiece is a good idea, since chucking that hub with those flanges will be a royal pain otherwise. I suggested chucking it internally (inside the bore, pressure pushing outwards) but a mandrel sounds a lot easier.

By the way, that 3" material can probably be used; just modify the hub so the flange is 3" OD and the rest of the dimensions get smaller by a little. The 1/2" shouldn't make much difference.

Don