[RMS11]

Yes, we would use a plasma cutter to cut the outside plates and a mill to cut the inside plastic. We dont have the machining capabilities to make a wheel from a block of aluminum, would take over 4 hours per wheel probably. For this design, we can make each wheel for about $25-30. This is significantly less than our wheels from this year. If we had the ability to weld, we would probably do something more like what Peter mentioned above. We would actually make these out of a rectangular block of delrin. We do not have access to a lathe currently, or else I would like to at least try a 1 piece wheel. And yes, the spacer is considered in the weight. It is made of 1/4" aluminum.