I have 6in. dia 6061 aluminum bar stock in my shop that was donated to our school several years ago. Can I use this to make our wheels. Small Parts does sell this material(page 97) in their catalog. I should not have to purchase it if I allready have it. Please advise.
Yah, you can use it, so long as you didn’t manufacture the wheels before the kickoff, and the wheels don’t damage the carpet.
I think that unless you buy the AL bar from Small Parts, it is not legal (since I can’t think of any way to get it in under the Additional Hardware rules).
Now, as it turns out, Small Parts sells 6" dia 6061 AL bar stock.
How are we to know that the bar you made your wheels out of is not from Small Parts?
While I am loath to encourage any violations of the rules, I am also a realist that looks to the spirit of the rule.
In your case, I wouldn’t loose any sleep over making your wheels out of the stock you have on hand.
Joe J.
The look really nice if you powder coat them and make some nice rims. If nothing else works on our bot, at least our wheels will look good…
here is a pic of our ‘short stack’ , just need a little machine oil and a dallop of graphite grease on top !
I would just go with the spirit of the ruling on that one…
I think Aluminum Bar Stock is/or may be an ‘extrusion’ so is in the unlimited parts catagory. Even if it was cast or rolled - how would
anyone know it wasn’t an extrusion - I can’t see how using your
aluminum is a violation of the letter or spirit of first. Our wheels in the past have been built of layers of plywood and aluminum plate cut into disks.
But Extruded Aluminium is limited to a 2"x3" profile and rods are limited to a 1" diameter. As Dr. Joe pointed out, I think the Small Parts aspect would be the only legally acceptable angle.
Well, if it’s under 1/4" thick, you could just say that they were cut from aluminum plates - which you could do if you have a mill and a rotary table (or a mill under CNC Control 
)
Even if you don’t have a lathe or milling machine, 1/4 inch aluminum is soft enough to be machined with wood working tools.
There was an article in “Fine wood working” magazine about
12 years ago on how to use a router with a carbide blade.
A circle cutter on a drill press would also work, but there are considerable safety issues.
The easiest way to cut a disk out of aluminum plate is on a metal
cutting badsaw with a thin blade. Drill a center hole and bolt the blank to a flat piece of scrap, so the blank can pivot into the blade.
Saber saws will also work on 1/4 inch plate, work slowly and pause often to allow the blade to cool.
The newer spiral blade saws I see on TV are advertized as being able to cut metal. but I don’t know if they’re suitable.
The rougher the initial cut, the more sanding and filing to get the final shape. You did want ROUND wheels?