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Re: pic: 4in Wheel CAD
4" diameter 6061 is a little over $5/inch on McMaster. Making a 1-piece wheel will be the lightest, simplest option. No threaded inserts, no delrin, no multi-piece wheels, no big bolts.
If you were to keep within the budget of $15-$20/wheel you could just about use 2024 or 7075 aluminum for your wheel.
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