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Hey all,

I recently decided to take on my first ever DIY electric skateboard build which you can see here

The build was a huge success so i thought id try and go a little further and cast my own wheels. So i thought id create an instructable for both the board and the wheels in case anyone is looking to do the same.

The first step was to decide what size wheels i wanted to cast and look into the best way to do it without spending a lot of money.

I looked into having aluminium molds made but that would have cost a lot of money and with this being some what of an experiment i didnt want to spend that. I have worked on a few projects in the past where i have cast my own parts so i decided to go down the 2 part silicone mold route. But first i needed a wheel to mold so i decided to make one using plaster.

I got a 1kg bag of plaster from hobbycraft and a 110 inside diameter pipe which i believe is used for drains.

Im lucky enough to own a laser machine so i used a piece of 3mm ply and cut a circle the exact same size as the pipe with a circle dead centre to ensure i got the 3d printed insert in the middle of the cast.

The reason behind the 3d printed part i wanted the wheels to be shaped like general wheels where the outside slopes in towards where the bearing is inside the wheel. So as you will see from the picture i created the 3d printed part to give me that when casting.

I then fixed the 3d printed part to the board using hot glue and made sure it was dead centre using the circle id cut. The did the same with the pip around the edge.

I then mixed the plaster and poured it into the mold. When designing the 3d printed part i made sure that the height of the part was exactly half of the overall thickness i wanted the wheel to be so i knew to stop right at the top.

Quick note that spraying the mold with mold release did help with removing the part afterwards.

Step 1: Plaster Cast Wheel

So once the plaster had set i removed the plaster wheel half from the pipe mold and repeated the process until i had both halves.

As you can see from the pictures they did need some cleaning up which was expected but the good thing about plaster is that its so easily sanded down and smoothed out.

I did a little bit of sanding on both halves before fixing them together, I wasnt too sure how i was going to fix them together but it turned out that just ordinary super glue worked really well so i just used that. Once i had them both fixed together i sanded the whole wheel so it was nice a smooth and then added some filler so fill in any air bubble holes, let that dry and then sanded again until i got a really nice smooth finish.

There were some small air holes still visible but that wasnt too much of an issue.

What was the total cost in materials?

What would you estimate the total hours of labor to be?
Cool. But isn't the main point of it that these are wheels, not just random dust collectors? They should roll, they should withstand slides, bumps, be durable etc. How do they perform?
chopperwalker5 months ago
This is great. I've always wanted to make on e-board from scratch and went back and forth about how to drive the wheels. Looks like a fun way to go. I wonder if you could mold in a timing pulley and go belt driven...