I had based the design of the cart on stock sizes of ERW steel tube that I already had so first job on the wheels was to saw off a couple of rings of each diameter. These were then faced off to 3/4" wide and the wall thickness reduced to 3/32". I would have liked to have gone down to 2mm thickness but without a 6-jaw chuck the rings would have distorted with the pressure from the jaws.

To save a bit of time and effort I drew out the basic shapes of the spoke discs and e-mailed the files to Lasermasters who sent me back these in 6mm steel which fitted the rims nicely.

First job was to machine some 2mm deep locating recesses and some hub halves to go into them which had a slight taper to represent the draft angle of a cast hub. The centre holes were left undersize at this stage.

It was then just a case of mounting the embryo spoke disc on the rotary table and milling down each side of the spokes to form the "+" section and then thinning down the remaining outer web.

With a bolt through the hub and some packing to raise the rim to half way it was just a case of silver soldering it all together.

After a quick soak in the acid pickle to clean things up the wheels were held in the 3 jaw chuck and the bore opened out to 3/8" which ensures they will run true even if anything moved during soldering.

I also made a few D-pins to keep the wheels in place, some square nuts and modified the stock heads of some M6 coach bolts to look a bit more scale plus a couple of square headed sets to lock the rear axle and fork retaining collar in place.

part one here  part two  part three part four part five part six