pic: 4in Wheel CAD

[RMS11]

Why do you shy away from delrin? This year, we found it easy to machine. We made our wheels out of it this year. As for the threaded inserts, how would you recommend attaching the side plates instead? I was looking for a way to avoid bolting all the way through, adding much unnecessary weight. This year we used standoffs, but that was expensive. Aluminum bolts would make it even lighter, if we could find a good option. I do like the idea of making the sprocket have more of a structural use.

Here is a picture without the sprocket attached:


Peter, could you elaborate on how this press fit worked? It sounds like a great idea and a way to avoid welding with aluminum. The tube you mentioned, did you just buy an aluminum tube from mcmaster? How were the tolerances? How did you keep the inside part from slipping?