I know this is a old post but this tip may help someone that wants to make wheels and use the plugs from the hole saw.
At one time I made many,many toys and they all took wheels.
The high price of wheels got to me and I had many plugs on hand so I took a Irwin drill and cut off the end (norm.sq.ends for a brace and bit drill) so it would fit in the drill press.
Then I took it to the grinder and a rat tail file, did a bit of rework on the cutter so it would cut out wheels with a center hub....the main part of the drill works great to make the hub. see snapshots below.
This tools works great, it will make wheels from 1 1/2" to 3" and I had one bigger but I can find that one right now but I did show a snapshot of the blades you can get to make them....(from Ace Hardware/Home Depot)
Note **** you will need to grind off the screw thread on the main head that's to say grind it to a point, this will let you control the cutter.
You will also need to make a quick jig to hold the plugs (hole saw) do one side and then flip it over and do the backside of the plug/wheel.
Note***the plugs make great dual wheels for the rear of a truck toy.
do one side of the plug and then flip it over and do the other side and then take it to the band saw and put in a v-slot to make it look like two wheels.
make a jig to hold in place in the band saw,two sq. blocks with a 1/4" dowel to hold the wheel in place,a wheel Sandwich jig.
For the advance wood toy maker ▼
If you want to put the look of tire on the wheels use the tool below,I used a old one I had around and it works great for this job.
Stick the wheel in a drill with a 1/4" bolt and hold it to the knurling tool.
knurling tool below
http://www.grizzly.com/products/h2984
http://www.grizzly.com/products/h7570
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IRWIN Lockhead bit from: ▼
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=6269278278&category=13872
http://www.hectorshardware.biz/shop/product.asp?dept_id=10203&sku=323004&
http://www.shop.com/op/aprod-p30496016-k24-g4-~irwin+lockhead-nover?sourceid=3
http://www.petesdepot.com/323004.html
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Hope this helps someone
Bj
