Classic Wheel Restoration "Build Thread"- Old-School 15x7 SenDel

[cobrawannabe]

Well, here is a thread covering the restoration of those uber-cool (to me, at least:lol classic SenDels I found at the "Saab Farm". They are certainly a rare set of classic gems which to me, go very well with the lines of the Focus, and almost look factory on mine.

Here they are in the condition in which I found them... WHOOPED!

This is the best of the four...


The picture simply does not do them justice. They have suffered outside for the past several years, completely uncovered and exposed to the elements. While still in service, they also fell victim to a SEVERE curbing, probably on multiple occasions. They are all missing a bunch of lip, but one in particular is completely missing about a 4" section! The pitting on some of them is severe, and oxidation has taken it's toll.

Since I picked them up about a week ago, I have started the project in earnest. This is my first major restoration, and I am willing to put in the time to do these right. If in the end, I decide not to use them, they will be sold; so I want them to be 100%

So far, I have...

-Cleaned thoroughly with Purple Power
-Stripped plastic coating off with TAL-STRIP II aircraft-grade coating remover
-Began rough sanding and removing pitting, as well as brushed the surfaces.

Here is how they sit ATM...
Before...


After...


There will be many updates as the project progresses, as well as better pics of the current stages!

Future plans are...

-Burn off current tires
-Sand down all pitting, and strip all paint
-Remove tires
-Weld in missing pieces of lip, possibly do so with severe pitting on the surface, as well
-Possibly cut and widen, MYSELF
-Fully polish the face and lip of all wheels
-Decide whether or not I want to paint anything.

[cobrawannabe]

UPDATE:

All wheels have been stripped, and I'm about 1/3 of the way through Step 1 of the sanding process...

Here is the worst wheel, which I am in the middle of Step 1 on... This thing is BEAT!

Whole wheel:


Bad spot on the face:


Bad spot on the lip:


And here is the wheel I have finished with Step 1:

Whole wheel:


Lip/face:


The two wheels were nearly identical in condition as far as finish goes. The "worst" one just had worse curb rash.

[Kielan]

If you're going to be fully refinishing these, I would take the tires off, makes life 8279467234906 times easier. What are the specs on these?

[cobrawannabe]

The tires will be coming off as soon as I can burn them to oblivion and get to my buddy's shop to dismount them.

The specs are 15x7 et35. If they get widened, they will be moved to a 15x8.5. Not sure on the et yet because I haven't seen the barrel yet to decide where I will cut them. That won't be for a while, though, since I need to make sure I can use Bacon Academy's TIG welder again. If that falls through, I have other resources.

And SWEET JESUS! 7,700 posts??????

[cobrawannabe]

Wheels were scrapped today after discovering a 6" crack in one of the barrels that was disguised by the black paint...

[Zic]

Wheels were scrapped today after discovering a 6" crack in one of the barrels that was disguised by the black paint...

ouch

[Kielan]

The tires will be coming off as soon as I can burn them to oblivion and get to my buddy's shop to dismount them.

The specs are 15x7 et35. If they get widened, they will be moved to a 15x8.5. Not sure on the et yet because I haven't seen the barrel yet to decide where I will cut them. That won't be for a while, though, since I need to make sure I can use Bacon Academy's TIG welder again. If that falls through, I have other resources.

And SWEET JESUS! 7,700 posts??????

You can't widen alloy wheels. Just a FYI. And yes 7,700 posts almost 7,800 haha.

Wheels were scrapped today after discovering a 6" crack in one of the barrels that was disguised by the black paint...

Sucks.

[rvolvor]

You can't widen alloy wheels.

wrong

[cobrawannabe]

You can't widen alloy wheels. Just a FYI. And yes 7,700 posts almost 7,800 haha.

Sucks.

You absolutely can, sir I will be widening a set of Eagles for a client who dirt races, and will post up pictures when they are done. Going 15x15 for a set of climbing scoops.

ouch

yeah, it sucks.

[Kielan]

How can you widen them...

[Stephen]

Basically in the same way they do industrial piping. Its just kinda a PITA compared to steelies

[Kielan]

I thought the barrels warped a ton when you did it, which is why no one does it.

[cobrawannabe]

I thought the barrels warped a ton when you did it, which is why no one does it.

Cut, add insert, weld, repeat

Any type of GTAW situation with aluminum presents a clear and present danger of warping (refraction, as well), you just need to know how to prevent it. If anything, there is less danger of warping when dealing with the thick barrels of an alloy as compared to a composite wheel. I normally like to make the cut, chamfer the edges of both halves of the wheel and the insert; then proceed. I never use much power, though, and keep the bead as thin as possible.

Here is a good example of what I am trying to illustrate, albeit poorly


Notice how each bead is relatively short? This is because the welder took his time, allowing the wheel to undergo it's natural heat cycles completely. The wheel was allowed to expand and contract in a manner in which it did not do so too quickly. While the beads are bit bit wide, that could be due to a shallower angle on the chamfers. He could have also built his puddles a bit more patiently, and moved more slowly. That would have given him more control over the heat spread, and kept the beads more uniform. Overall, it is a pretty nice example.

[Zic]

of the famous m roadster, that fmu build.
for more-

http://forums.bimmerforums.com/forum/showthread.php?t=1218283