Making cambers in the garage with their own hands
Let’s start with the machine that helps to do the main part of the operation. In order to cut the disk, we need here such a frame, which consists of two main units – it is a stop, on which the VAZ hub is mounted. It also has an adapter for different razboltazhka.
Stand is set exactly 90 degrees relative to the plane. Also parallel to the mounting plane and parallel to our bed is a stop for the grinder mount, which is lowered onto the disk for an even cut.
With the disc mounted on the hub, it is sufficient to tighten the two bolts. This is enough to center the disk. Next, put the grinder down on the disk.
Adjust to the width where you want to cut the disc. The grinder is mounted on a rigid lever, so it has no travel to the left or right. We lower the grinder to the disk, and we make a cut on the disk, holding it with the hand by the handle.
After we’ve made an even cut, use a hammer to gently knock down the outside of the disc.
On the outside of the cut disc we will weld a plate 3 inches wide – 8 cm. It is better to order such a plate at the factory, where it will make the desired length and width. For example, the length you need for a R-13/14 disc is about a meter.
The plate is better to take a little longer so you can adjust it directly to the disc in the process. The necessary thickness of metal is 3mm, this is quite enough. We bend the plate to the required radius on a special stand.
It is necessary to bend it evenly, so there would not be sharp bends. Finished plate on the outside of the disk, it should fit the radius, it should dock well with the disk.
Install the ready plate on the cut off part of the disk and start leveling. The size of the installed plate is clamped by a clamping clamp.
The whole thing is tacked by welding points in a circle, the excess metal is cut off from the plate.
Then the entire workpiece is tacked to the hub part of the disk.
Now look at the runout of the disk. Rotate the disc relative to the hub part until the smallest disc runout is established.
When properly fabricated, you get an unbalance, the unbalance is about 30/40 grams. When you have found the desired position of the workpiece relative to the disc, tack on points the outer part of the disc to the main, hub part, and also tack on it by spot welding.
It is necessary to tack welding by spot welding to prevent the disk blank from drifting during the manufacturing process. When the disc is tacked and the runout is minimal, you can safely weld the joints with a solid seam.
The weld should be tight, without interruption if possible. If you are making a camera weld, it is best to deburr the seams so that the camera does not fray during operation. If you are doing a tubeless tire, the seams should be sealed to prevent air leaks.
In the process, the disc is not quite straight, you can go to the nearest tire shop for rolling discs.
Now you can paint the disc, put on the new rubber and install it on the car.
How to make the discs with your own hands
Many car owners are trying to give their car some personality to make it stand out from the crowd. In this case, what tricks they do not go, ranging from banal stickers on the windows and the body, and ending with a fairly serious rework the body and external elements.
What are swagels?
Lately another car tuning has become popular which deals not with a body, but with wheels, during which they change wheel disk geometry homemade, thus allowing installing tires of increased width on the car. Such modifications of disks are called “flared”.
It is noteworthy that there is practically no use of such modifications. But since installing the flared discs allows making your car stand out a little bit, this kind of tuning is now in quite good demand.
Of course, you can just buy extra wide disks, but they are expensive and not all models can be fitted. And the modification of the disk is available for any car, even for the old Moskvich.
The entire fabrication method of flared discs involves only cutting the disc and placing an insert between the halves.
There are a few technologies of cupping fabrication, and below we will consider the most common ones.
Advantages and disadvantages
But first let’s note what the wheels of increased width installed on the car provide.
Of the positive qualities from their use are noted:
- The original, non-standard appearance of the wheels;
- Ease of fabrication with minimal cost;
- Increased tire contact patch with the road due to greater width, which affects the passability of the car.
This is where all the positive qualities of the set of swaps ended.
But there are more disadvantages of such tuning:
- Increased fuel consumption;
- Decrease of car dynamic characteristics;
- Decrease of controllability of a car at high speeds;
- Increased load on the axles, which leads to premature bearing wear.
This may also include the complexity of finding a wider tire, because the standard ones will not sit on such a disc.
And making changes in the design of the disk itself will certainly affect its strength indicators. And no matter how qualitatively they were made, they cannot be considered as safe.
And finally, though it is trifling, but all the same – a disadvantage. The car with installed flared wheels will have to be washed much more often, as the edge of the wheels will stick out for wings.
Because of this, entering even a small puddle will be accompanied by abundant splashing of car’s sides.
Therefore, you should think it over well before starting to make a wreck, because you can make your car unique in other ways.
For those who have decided to equip their car with such discs, it will not take much.
“Donors” to create a wreck are the usual steel stamped discs. Cast for this will not work, as their material is very difficult to weld, and in general, any intervention in their design is fraught with serious consequences.
Steel disks are inexpensive, easy to work with, and they are well welded, and you can not create them without welding works.
First, let’s go over the construction of the stamped disc itself. It consists of the disk itself (with central and mounting holes) and the rim with sides, on which the tire sits. The rim sits on the rim and is welded to it.
There are two basic ways to make an over-welding – from two rims (simpler, but more costly) or by using an insert. And the second method may differ in the way it is done.
So let’s consider each of them in more detail, and on the example of specific cars.
Welding from two discs
The first will be a car VAZ-2108. In general, the described technology is suitable for virtually any car of the VAZ family, as by design discs they almost do not differ.
Below will be described how to make raveling from two disks.
The peculiarity of all the works is to make all the cuts as even as possible. This applies not only to the brews obtained by this method, but in general, to all.
For cutting, it is best to use a lathe, where it is possible to evenly clamp the disc. But the possibility of using such equipment is not everyone, so to make the necessary product in the garage conditions will be required:
- Measuring tools (ruler, caliper);
- The wheel hub;
- Angle grinder with cutting discs (“Bolgarka”);
- The welding machine;
- Seam sealant.
To make the cut as smoothly as possible, it is better to make a device out of the hub (any hub will do, the main thing that the wheel rim sat evenly and you can fix it). Its essence is a shaft, on which the hub with bearings is put.
This shaft is fixed on the base (table, flat floor), and the position of the shaft must be strictly horizontal. That is, it is necessary to install the device so that the disk stood without tilting.
Also, for the convenience of work, you can make a holder for “Bolgar” from improvised means, and mount it on the same bed as the shaft with the hub. And the holder should provide an opportunity to move the “Wiggler”.
There is another way.
Having prepared the tools and devices, let’s get down to work:
- Since the discwelding will be made of two discs, each of them must be properly cut;
- We take the first disc, fix it on the hub. We cut it in the place where the disc bends and forms a plane for the rim fitment. But the disk itself and the part of the rim that is welded to it should not be affected. The diagram shows it more clearly:
All that remains is to paint the disc, put the rubber on it, balance the wheel and install it on the car.
The described method is inconvenient because it requires two disks for making one over-welding, which somewhat increases the costs.
Welding with a spacer
The second method, does not require as many disks, one set is enough. But in terms of execution it is more complicated.
Let’s consider it on the example of the car VAZ-1111 “Oka”.
The peculiarity of this car is that it uses wheels with a diameter of 12 inches.
The method described below is reduced to the use of the spacer. Of the tools, in addition to those described above still need the presence of a rolling machine and 4 flat strips of sheet metal thickness of 3 mm, width 50-60 mm and a length of at least 1.5 m.
Razvarki by this method is done as follows:
The cutting of the disk is performed. The cut is made in the same way as the first half of the above method (near the disc bend to fit the rim);
Welds with spacer, second method
The latter method of making the unwelds is identical to the spacer method. The only difference is the location of the cut. An example in this case will be the UAZ car.
The essence of the work is the same as for “Oka”. Prepare the disk and cut it, but not at the junction of the disk with the rim, but at the bend of the rim flange. In the photo you can see where the cut is made:
And then everything is identical, we prepare metal strips, bend them on the rolling mill, attach the ring, center it, “tack”. After checking the alignment, we weld the joint around the circumference. The only thing left is to paint the disk, put on rubber and balance.
The ready disk looks like this:
In conclusion, let’s note that all works are modifications of the disc design. In factory conditions the products are tested for durability, and only after that they are placed on the market. And here making a disc crack in garage conditions nobody will guarantee its safety.
Therefore, if you do not have sufficient skills in welding, it is better not to weld the disk yourself, and to seek the help of an experienced welder.