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Re: Sand casting?
you might try ceramic shell or some sort of investment casting instead of sand. If you can make a wax model of what you want or a rubber mold of the original you can fill with wax you may be able to do the burnout in a ceramics kiln or similar oven.
What kind of equipment do you have?
Erik is right that the undercuts that the center around the axis will be a real bear to cast. How big is this hub? The thinness of the spokes will also be an issue requiring pretty hot metal.
Of course if you are casting ferric stuff expect oxidation to be an issue. Any time you cast a very reactive metal (iron, copper etc) it is a good idea to cover the crucible with an inert gas like Argon.
YEARS ago I worked as a caster with precious metals and some brass/bronze. I can see how I would make this with the equipment I had then but all that was investment based and not too improvised.
Hope it gives some ideas
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