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Reply to: How to make your own beach wheels

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[quote=carolinacatamarans]Every once in a while someone comes along and asks about homemade beach wheels convinced they would be much cheaper than a set from cat-trax.

I decided to make 2 pairs for myself to see if indeed it is any cheaper, I will also share costs and processes.

This project started when I was at the local scrap yard and saw a set of aluminum golf cart wheels that were set aside for sale. I started thinking that these could easily be turned into cat-trax. The next step was to purchase some .5" aluminum plate and some 3" aluminum tube. I paid $25 each for the wheels, $35 for the tube and $40 for the plate that is pictured. The stick of 2" .125 tube for the axle was $140. Smooth tires are $65 each.

[IMG]http://i46.photobucket.com/albums/f149/black92se/null_zps9a12e169.jpg[/IMG]

Here is a general mock of how the tube fits in the wheels (it doesn't)

[IMG]http://i46.photobucket.com/albums/f149/black92se/null_zps1734c4f1.jpg[/IMG]

The first step was to cut some 6" hub flanges for the wheels I did this by loading a big hole saw into the drill press. Mark carefully to get the most out of the plate.

[IMG]http://i46.photobucket.com/albums/f149/black92se/null_zps3260495a.jpg[/IMG]

You will probably need to make your own heavy duty arbor, none of mine where up to this job. (Your obviously using the larger diameter in this picture)

[IMG]http://i46.photobucket.com/albums/f149/black92se/null_zps494e0ea5.jpg[/IMG]

Your left with this circle.

[IMG]http://i46.photobucket.com/albums/f149/black92se/null_zps8d0564c1.jpg[/IMG]

The next step is to open up the flange to allow it to fit over the 3" tube. I did this with another smaller hole saw. I did not take pictures but it is the same idea as above. After this I cleaned up the rough cut from the saw.

[IMG]http://i46.photobucket.com/albums/f149/black92se/null_zps254d8f4e.jpg[/IMG]

Next I marked the flanges and drilled and tapped them. I used .5" wheel bolts.

[IMG]http://i46.photobucket.com/albums/f149/black92se/null_zpse9ae3ffe.jpg[/IMG]

I built a simple jig to help hold the flanges evenly on the tube for welding. Use small tacks to get started.

[IMG]http://i46.photobucket.com/albums/f149/black92se/null_zpsb70edf8c.jpg[/IMG]

[IMG]http://i46.photobucket.com/albums/f149/black92se/null_zpsa1b8fa15.jpg[/IMG]

After welding both sides of the plate I chucked the hub back into the lathe to face it up.

[IMG]http://i46.photobucket.com/albums/f149/black92se/null_zpsb8f4f7a4.jpg[/IMG][/quote]

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