self made aero wheels

[David99]

Thanks everyone! I really like the plain silver look that (almost) matches the car's paint. This week is pretty busy for me so I won't have time to do a real controlled test. A few things I have learned so far:
Aluminium is a very soft metal. Very easy to drill and machine, but too soft for a thread that is used a lot. The friction of just putting the screws in and out wears the thread out. I have two possible solutions for this, but that's further down the line.
The disks vibrate a little and create some noise. Not bad, but if you turn off AC and music you can sometimes hear it a little. Mostly because they are attached on the outside while the center is loose. Easy to fix, but again, not a priority right now for me. I think the flat shape is the worst when it comes to vibration, too.
Each time you want to check the tire pressure you have to take them off. Drilling a big enough hole in them to reach through to the valve would fix it. Not sure I want to.
My goal is to show there is hopefully enough of a benefit of having closed wheels that either Tesla or a different manufacturer starts making a real aero rim that is closed and smooth. Not a fake one that still has holes and pretends to look like a normal rim. If anyone knows a company that is willing to custom machine rims, let me know.

 

[Larry93428]

In aerospace to achieve a durable threaded hole in aluminum and even magnesium, we used Helicoils:
Wire Thread Inserts | Screw Thread Inserts | Stanley Engineered Fastening
.
I like the look of the wheel covers.
(I was considering whitewalls before I bought my Model S. Still would like to see someone try that.)
~Larry

 

[JRP3]

Rivnuts are also an option: Your source for Rivnut engineered fasteners and installation tools - Cardinal Components

 

[David99]

Rivnuts are also an option: Your source for Rivnut engineered fasteners and installation tools - Cardinal Components

Can they be installed in a hole? I never used them and it looks like they are made for hollow objects or sheet metal.

 

[linkster]

to achieve a durable threaded hole in aluminum and even magnesium, we used Helicoils:

+ 1

- - - Updated - - -

Rivnuts are also an option

- 1

 

[Matias]

.
My goal is to show there is hopefully enough of a benefit of having closed wheels that either Tesla or a different manufacturer starts making a real aero rim that is closed and smooth. Not a fake one that still has holes and pretends to look like a normal rim. If anyone knows a company that is willing to custom machine rims, let me know.

http://evannex.com/

sells all kinds of Tesla accessories and also manufactures some. They might be interested.

 

[WarpedOne]

The disks vibrate a little and create some noise. Not bad, but if you turn off AC and music you can sometimes hear it a little. Mostly because they are attached on the outside while the center is loose. Easy to fix, but again, not a priority right now for me. I think the flat shape is the worst when it comes to vibration, too.

Those plates should not be completely flat - make them concave a bit i.e. the center should be 'pulled' out about half an inch. Any machine shop can do that for you.
On the inside center you should fix some hard rubber to support the plate shape.
This should dampen vibrations and further improve airflow. Air does not run straight along the wheel but goes in a curve.

And don't forget to balance the wheels with plates attached.

 

[bxr140]

In aerospace to achieve a durable threaded hole in aluminum and even magnesium, we used Helicoils:

For the wheel's environment, keenseets are even better. Locking keenserts doubly so.

Alternatively, one could epoxy a nutplate on the back side...The spokes are hollow-ish.

 

[jerry33]

And don't forget to balance the wheels with plates attached.

I doubt the aluminum plates will have much effect on the balance as they are closer to the centre of rotation than the tires.

 

[wycolo]

I'd like to see the screws or bolts being used. I'm guessing self tapping might be good for dozens of removals but be eventually replaced with plastic tubing (the plastic anchor concept). With plastic anchoring the rim holes would never wear out, just the replaceable anchors.
--

 

[WarpedOne]

I doubt the aluminum plates will have much effect on the balance as they are closer to the centre of rotation than the tires.

Vibrations don't mind the doubt.

 

[JRP3]

Can they be installed in a hole? I never used them and it looks like they are made for hollow objects or sheet metal.

- 1

Opps, I was thinking of putting threads in the wheel covers, not the rims :redface:

 

[huntjo]

Those plates should not be completely flat - make them concave a bit i.e. the center should be 'pulled' out about half an inch. Any machine shop can do that for you.
On the inside center you should fix some hard rubber to support the plate shape.
This should dampen vibrations and further improve airflow. Air does not run straight along the wheel but goes in a curve.

And don't forget to balance the wheels with plates attached.

The shape you are describing "pulled out" is actually convex. Not concave.

 

[WarpedOne]

Depends entirely on your POV

 

[David99]

Sorry still no time for a controlled test, but here is a photo of my car with all disks installed. I am getting a lot of positive feedback for the looks of the wheels. I was expecting more of a 'what in the world is that'. But so far I have gotten almost only positive comments. The fact that they almost match the car's paint helps.

 

[mhpr262]

That looks seriously cool. Very futuristic, like something out of "Bladerunner".

Someone needs to mail Elon this pic! We want the aerowheels back, and this time make them good-looking, please!

 

[JRP3]

I think Elon knows what pizza pans look like.

 

[billarnett]

I'm very eager to see the results of a controlled test. This sure looks like an easy way to save a few kWh.

Did you ever think of making the disks out of clear plastic? They might look better that way, almost invisible. (Not that they look bad now

 

[jerry33]

I'm very eager to see the results of a controlled test. This sure looks like an easy way to save a few kWh.

Did you ever think of making the disks out of clear plastic? They might look better that way, almost invisible. (Not that they look bad now

The problem would be to find a plastic that wouldn't get scratched up after a couple of weeks of use. Brushed aluminum is probably the best bet.

 

[JRP3]

Not to mention the dirt, mud, brake dust, etc. that would probably show through from the inside.