Superstar aluminum wheel GR-MAX bolt cover production 【restoration of old car parts】

We are doing custom parts production in Toyokawa City, Aichi Prefecture.
Industry love.

Thank you for your hard work this week.

Now, Japan is in the midst of a typhoon.
We would like to extend our deepest sympathies to those who have been affected.

It seems that there is no damage to that extent in industry love,
I am grateful to be able to work safely today.

Well, this week I made a wheel cover as I wrote in the title, so I’ll introduce it.

Industry Love also has LINE,
I can somehow get inquiries from that line.
By the way LINE_ID: 665zvyfx is. You can also access from the QR code below.

LINE QR code

Of course, we also respond by e-mail,
There are many inquiries about parts restoration, so please send us a picture of the parts, etc.
Communication on LINE is very convenient, so please take advantage of it.

So, I think it was from the initial inquiry over the phone, but after that, we communicated on LINE and the story progressed.

I received a call from Mr.
On the phone, I was told that one of the four aluminum wheel covers was damaged or lost, and I was asked if I could make one.
At first, I thought it was a plastic cover that protects the entire side of the wheel, but after sending me a picture on LINE, it turned out to be a metal cover that hides the bolts that attach the wheel.

Photo received

It would be helpful if we could communicate by phone rather than by email, but it is very helpful to have a picture because it is often difficult to get an image of the product through verbal communication alone.

I thought that if it was plastic, it would be made with a 3D printer, but if it is metal, the story is different.
This time, the shape is like a round plate with a hole, so I knew it was time to use a lathe.

Image of lathe processing (photo from the Internet)

We decided that it was possible to make this, so we asked you to send us one of the remaining three covers, from which we read the shape and proceed to production.

By the way, reverse engineering is to analyze and restore existing parts and use them for new designs.
Today, with the development of 3D scanners, etc., reverse engineering is becoming easier.
However, it is not the case that anyone can reverse-engineer if they read it with a 3D scanner. Knowledge and experience are still necessary to think about materials, accuracy of holes, and manufacturing methods.

When I look at the parts you sent me, I can tell from the surface on the back that they are made by forging.
Forging is a method of shaping metal by forging it.
The advantage is that it is suitable for mass production, and the strength of the material increases because it is molded by hitting.
The disadvantage is that the mold requires a press machine, so it is almost impossible to make only one.
It is difficult to control the overall precision when making numbers.

As you can see from the disadvantages, it is difficult to use the same manufacturing method as for mass production when manufacturing individual parts.
In this case, the cost of preparing the forging die and press machine would be very high.

Therefore, there are many patterns that are generally cut out in one creation.
Recently, there are 3D printers that can mold metal,
The hurdles are still relatively high because the materials are limited and sintering (like quenching) is required to increase the strength.

This time, as usual, I decided to cut it out and manufacture it by lathe processing.
Another problem was the material. I thought it looked like iron, but just to be sure, I measured the mass.
When I calculated the volume and calculated the specific gravity, it turned out that it was made of aluminum. I thought that things were certainly light.
By the way, the specific gravity of iron is about 7.85, and the specific gravity of aluminum is 2.7, so there is a difference of 2.9 times.

If this is the case, measure the shape of the actual object and make a drawing and ask the lathe shop.

Parts made by a lathe shop

Done, done!!
And it doesn’t stop there.
Aluminum wheels are parts that are used outdoors, so they must be properly surface-treated to have an anti-rust effect. Anodizing is performed there.
Simply put, it tries to suppress other rust by putting a hardening rust called oxide film on the surface of aluminum.
Alumite can also be dyed with color alumite.
In principle, the anodizing process creates invisible holes in the surface, so I put dye in the small holes and close them later.

This time, it was originally painted black, so I asked for black alumite, which is close to it.
We also make decisions based on customer requests on a case-by-case basis, so please feel free to contact us.

And this part is finished.

aluminum wheel bolt cover
finished product

Isn’t the convex shape in the hole disappearing after this copy source and copy? It will be.
To be honest, I don’t know the reason why there is no hook on the wheel side and it has a convex shape.
It was discontinued after consulting with the customer.

and delivery.

I received the word “perfect” from a customer.
The concept of Industry Love is to “create a perfect fit”, so I couldn’t help but give a fist pump.
Thank you very much Mr. N. 😊

By the way, one advertisement,
When cutting out this wheel cover, the parts are very thin, so it is difficult to shave due to vibration.
I made a jig (a part to fix parts) in a hurry.
Currently, jigs are manufactured free of charge and are sleeping at the processing shop.
So, if you are looking for the production of this wheel cover, please do not hesitate to place an order with Industry Love.
I think it’s cheaper than making it to other companies. (I think this service itself is rare)

Superstar aluminum wheel GR-MAX bolt cover

Thank you very much for your support.

Thank you for reading today.

Industry Love
Industry Love
address:〒442-0051 愛知県豊川市中央道3丁目31番地
address: 3-31 Chuo Expressway, Toyokawa City, Aichi Prefecture 442-0051
Inquirer: Nakao