DIY Network

'48 Indian Motorcycle: Building a Wheel Learn how to build a motorcycle wheel from scratch, spoke by spoke. From "Classic Rides" episode DCLR-302

The front wheel of DIY's project '48 Indian Chief is in almost as bad shape as the brakes, so to save a little money, host Craig Reynolds and antique motorcycle expert Chris Matthews build a replacement from scratch.

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	The old wheel of the '48 Indian Chief has problems — the front rim is bent, some spoke nipples are rusted and the seal on the hub is bad.
	Chris Matthews demonstrates how the spoke nipples — seen here — are inserted.
	The lacing process takes time. Be sure to concentrate and get each spoke correct the first time because you don't want to go back and re-lace, which means a spoke or two may have to be cut.

Material/Tools for all Projects:

1948 Indian Chief Motorcycle
complete set of shop tools
bike jack

Materials/Tools for Building a Wheel:

complete set of wrenches: SAE or Metric
new rim
new hub
new spokes
new spoke nipples
spoke wrench

Building a Wheel

Note: The project wheel is a 40-spoke rim and hub.

1. The first step in building a wheel is lacing the spokes, and the first step in lacing the spokes is dropping them in the hub.

2. The spokes are inserted in the hub two ways, inbound and outbound. The inbound drop in toward the center of the hub and the outbound are placed in facing the outside of the hub. So, within each flange of the hub, place spokes in each hole, alternating between inbound and outbound.

3. Once all of the spokes have been placed in the hub, lay in on its side on a flat surface.

4. Lay the rim on its side, surrounding the hub.

5. Start at the valve stem hole, and attach the first outbound spoke to the rim, giving the nipple a couple of turns.

6. Working counter-clockwise, the next outbound spoke will attach to the fourth spoke nipple. Continue with this pattern all the way around the wheel.

7. Now working clockwise, take an inbound spoke, cross it past three of the outbound spokes, attach it to the rim and tighten the nipple a few turns.

8. Continue this pattern all the way around the rim.

9. Flip the wheel over and repeat steps 4, 5 and 6.

	Figure A
	The trued wheel is ready to hit the road!

Truing the Wheel

Note: Truing is the process of adjusting the tension on the spokes to align the rim with the hub.

1. Once the wheel is built the spokes will need to be tightened and trued. Place the wheel on a truing stand and give it a spin (figure A).

2. Notice where the wheel hops up and down and where it sways side to side.

3. The rim should be trued to eliminate the hop first. Set the marker on the truing stand at the highest point the wheel hops. Note the point on the wheel and rotate it 180 degrees.

4. Tighten these four spokes a couple of turns. Repeat this process, working around the rim until all unevenness is eliminated.

5. Once the wheel is balanced, it's time to true the side to side movement. Again, set the marker at the point that the wheel sways out the most. Rotate it 180 degrees and tighten these four spokes a few turns.

6. Continue around the rim until all side to side movement is removed.

7. Once the wheel is completely straight, go around the circumference again, giving each spoke one final turn.

RESOURCES :

Welders
Lincoln Electric
Website: www.lincolnelectric.com

Kiwi Indian
Website: www.kiwi-indian.com

V-Twin Mfg.
Rims, Spokes, Hubs, Tire Irons and Truing Stand
Website: www.vtwinmfg.com

Motorcycle Lift
Handy Lift
Website: www.handy-lift.com

Various Tools
Eastwood
Website: www.eastwoodco.com

Hepavac Asbestos Vacuum
Bullseye
Website: www.bullseyecorp.com

Parts Washer
Safety Kleen
Website: www.safety-kleen.com

Chrome Polish
G & H Metal Finishers
282 Dakota St.
Paterson, NJ 07503

Belt Grinder
Ellis Manufacturing
Website: www.ellissaw.com

Powder Coating Shop
Best Signs
Phone: 865-922-5247
E-mail: bestsigns@tds.net

Coker Classic White Wall Tires, Tubes and Spoke Covers
Coker Tires
Website: www.coker.com