Start by cutting a normal sized empty spool of thread in half. Size depends on the size of rim you need. There are a few different sizes on the market.
I get foam from the bodyshop I work at. Lots of different kinds around but the kind I use is really ridgid. If interested look for the kind in Hood packaging the keeps the corners from getting bent. Otherwise use the foam you can find elswhere.. Here in the pic I used a large holesaw first then the smaller to cut out the rim.
Sand the rims to get glue to stick
Use a super de duper type of glue to get the foam to slide on and stick to the rim.
Wipe glue before it dries.
Find a bolt long enough to fit through rim and into a drillpress or hand drill. Make sure bolt is a snug fit width wise in rim!
Nut both sides of rim to make sure it does not spin on the new rim.
I use an air drill.
Start with 36 grit sand paper and then finer like 80 and then 180 grit to finish
Don't forget to round off the edges.
I then take a piece of thin plastic wrapped with 180 grit sand paper to make the ribs.
Before and after. Once you make the first take a micrometer measurment and you are ready to start sanding the next to size.
Finished set.
Up close. These are very light. Maybe lighter than most factory wheels since spools are thin. Rims are paintable too.
Hope you liked the ideas.
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Do you think it would work to use one spool per wheel (cutting out the middle section) so that each side has the edge rim? Maybe just depend on the holding strength of the glue used?
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As for the double flange rim. Yes this idea works. The type of glue you use on the foam can double as the rim glue. I use very expensive auto body epoxies. Like 3M because it is a perk of having it available from my job. Hobby 2 part epoxy is just as resourceful and recommended as well.
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In the same sense may I ask why you are on this site???? If you could buy a plane RTF. Why then are you surfing a scratch building site?
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