Ferrari 156 sharknose replica build…
When you cant afford a proper Nardi wheel, you have to make one from scratch. I’ve never done this before, but here is how I’m doing it on a whim with basic tools and years of woodworking experience.
EDIT** The aluminum is .188 thick 5052 grade.
The aluminum center spoke shape is laid out all from a center point. Corner radius’s are cut with hole saws and then cleaned up with a die grinder. Then I rough cut it out with a band saw and a jig saw. I set up a router with a radius jig and a straight bit and fine cut the outer ring to a perfect circle from that all important center point.
I used a straight bit with a top bearing, and a straight edge to router and fine cut the spokes.
For the wood I’ve wrapped mahogany veneer around a jig/form that I routed out using my radius router jig. I’m using a polyurethane glue. This is insanely messy and takes a second pair of hands.
I made 2 of these mahogany rings.
(If I did it again, I would use wood edge-banding from a continuous roll, and ideally a urea-formaldehyde glue. It would be faster, easier, cleaner, and the glue dries harder, and can be set by heat if you want it cured and workable within a few minutes.)
Once cured, I leveled off the top so the wood is flush with the jig/form. Using that all important center point, I cut the outer edge with the router, then I cut a dado with the router so the aluminum ring can be inlaid into the one side, and then cut the inner edge. With the polyurethane glue, the wood ring needs to be cut from the form carefully, and have the back side cleaned up on a sander. This is the face ring. The other wood ring is the back ring that will not get a dado cut into it, but otherwise will get the same process/treatment.
Both halves get a bull-nose routed on their face surfaces and will eventually get glued and riveted back to back, sandwiching the aluminum in between. the back side of the wheel will get finger notches filed in by hand and smoothed, and the back side rivets will be visible. the front side rivets will be hidden by another small dado that will then be filled with forged carbon fiber (Nardi likely uses ebony, but i thought carbon would be more fitting given the rest of the car).
Before mating the 2 halves the aluminum will get fully drilled, finished and polished, then ill tape it off, fasten and rivet everything, inlay the carbon, do a final sand and seal the wood with a polyester finish.
To be continued….