[Ianworld]

My team while we have some aluminum wheels waiting to be mounted tomorrow have been using effectivly wooden wheels. They're really easy to make. You take a 1 inch thick pieces of squarish plywood and drill rough centers(1/4" for simplicity) exactly the radius you want from one side in them. Then you take another piece of wood and drill a 1/4" hole in it. Stick a bolt through your rough center and this other piece of wood and clamp the second piece of wood to bandsaw so that the edge of your 1 inch thick plywood sits flush against the bandsaw blade. Then just turn the bandsaw on and twirl the plywood around the bolt you put through it. Makes a roughly circular wheel.

We covered these wooden wheels with some reasonably thick rubber (1/2" thick) which got rid of any non circular portions pretty well. You also have to drill holes in the wooden circles to mount sprockets, pulleys or gears to them. I'd suggest this for any team who wants to start making their own wheels.