No Lathe Trike Hubs - Page 1 of 5

Figure 1

First of all, thanks all of those who visit the Atomic Zombie forum and help others with advice and offer their great tips and tricks. There have been two alternative ideas posted in regards to creating the hub flanges that I use on trikes and quads such as the DeltaWolf, Kyoto Cruiser, Street Fighter, Gladiator, and Lode Runner.

One alternative to the machined disc is to cut the required flat bar or plate using the appropriate sized hole saw. The other alternative is to source out precision made washers of the appropriate size. Often these washers are called "fender washers", "dock washers", or "aircraft washers".

I'd like to present another alternative to the machined discs that only requires the use of an angle grinder, and hand drill. This procedure takes about 2 hours for all four discs, and is very effective if you don't mind spending a little quality time with your angle grinder. Since the hub flanges required in the plans vary in size, I will not be posting measurements here, but the same procedure will work on all trikes that use the hub-axle system I have developed.

Figure 2

The flat bar needs to be at least as wide as the discs you plan to make, and the required thickness. This flat bar is very easy to acquire, and can often be found in the welding isle in many hardware stores. You will need enough material for four discs, which is the number of discs needed for a delta trike or quad.

To begin, I traced two of the discs using a paper template that was made in Photoshop and then cut out. The traced circles are the same diameter of the flanges from the original hub because I am using the rim and spokes from a complete wheel that used this hub. The center of the disc must be marked and punched before any cutting, as you do not want to lose this center position. The punched center will later be drilled for the axles. Also, use a marker that can hold up to a little abuse as you will be grinding and handling the discs with gloves.

Figure 3

As shown, the discs being cut from the flat bar using a few straight cuts around the circumference with a zip disc. 8 or more cuts are made just outside the marker line so that final grinding does not take much time.

Figure 4

After a few minutes of cutting with the zip disc, the rough cut part is liberated from the flat. Notice how none of the cuts are inside the marked line.

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