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Hot Bot 2001 & 2002 made their wheels by cutting the center plate with the flames and bolt pattern out of what looked like 1/4" aluminum, then wrapped aluminum around the circumference to add width and welded the two together and then added traction material. It was very effective.
Someone from Hot Bot can probably fill you in with pics. Other than that 6" Aluminum Round Stock was the largest you could use to make 'billet' rims for your bot.
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