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Originally Posted by Richard.Varone
I'm not sure if you've had different results, but for us normal lathe tooling didn't work very well and found that a file worked the best.
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You need to use a very sharp tool to avoid just ripping up the wheel, but it can be done. For this case, I'd just use a file since you are taking off so little and you want to take off *just* enough for smooth turning but no more than you need to.
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If your wheels are spinning at the same RPM, wouldn't this cause issues with the actual contact speeds of the wheels being different? It seems to me that the larger center wheels would lose traction often and cause your drivetrain to "skip" or at least decrease the smoothness of the drive.
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The very, very small diameter changes required to make this work would have a negligible effect on speed - seriously, this is taking about around 1/16th of an inch off the diameter of a wheel, maybe 1/8 if you're pushing it.
My experience in FIRST has taught me that, whatever you do, make sure that no single failure can eliminate half your drive system.[...] The worst feeling in the world is having your robot driving around in circles when there is critical business to be done on the playing field. - Andrew [more] 
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