Victory!
Went milling today, got the wheels done. Here are some pictures. They still need to be cheeseholed, but meh. we've 7 more to go!
(sorry for low-res, taken on my camerafone)
Blanks
http://i27.photobucket.com/albums/c1...456/Blanks.jpg
Initial setup
http://i27.photobucket.com/albums/c1.../MillSetup.jpg
Closeup of the jig
http://i27.photobucket.com/albums/c1...tupCloseup.jpg
First cut
http://i27.photobucket.com/albums/c1...6/FirstCut.jpg
Second cut
http://i27.photobucket.com/albums/c1.../SecondCut.jpg
Assembled
http://i27.photobucket.com/albums/c1.../Assembled.jpg

(NB - the steel rule is a 6" scale)
We didnt really NEED a mill, we could have done this with a drill press =p. As long as you can get the blanks, you can make these mecanums with a drill press and bandsaw. but a mill is nice =p.