Build Your Own RC Plane Spoke Wheels!
Easy method using thread and the "lost jig" to build your own spoke wheels
Build your own thread RC plane plan spoke wheels - no special tools required
Spoke wheel for the Chickadee RC model plane
Spoke wheels are almost a requirement for building a scale RC model plane, such as the 1912 Blackburn or 1909 Demoiselle, that flew in the era before World War I. These early pioneers of flight, from the time period of roughly 1907 to 1914, made truly remarkable progress with the art and science of successfully flying an airplane. Note that spoke wheels were also very common in aircraft used during World War I such as the Fokker D.VIII. Aircraft construction techniques, engines and basic airmanship skills all advanced at a very rapid pace.
Due to their light weight and inherent strength, spoke wheels were a standard feature on all these aircraft. It has always been a challenge, however, to build your own RC airplane spoke wheels for indoor model aircraft. A model’s spoke wheels need to be strong, yet lightweight for the indoor flyer. Building spoke wheels usually involves constructing complex jig arrangements to properly install the spokes to the wheel rim. One can purchase spoke wheels on the market place, but they are expensive, and oftentimes too heavy for typical indoor model aircraft use.
Below is are the first two pages of the spoked wheel article published in the February 2010 Quiet and Electric Flight International magazine. These wheels will look great on a plane like the Pietenpol Air Camper.
Q&EFI spoke wheel pg 2
Quiet and Electric Flight International article on spoke wheel, pg 1
Following is a very simple to follow method for producing your own indoor RC model spoke wheels, from easily adaptable plans, using what I call the “lost jig” method. Using common modeling tools and building materials of balsa and plywood, a brass tube, thread and neoprene fuel tubing, you can easily and quickly make convincing RC plane plan spoke wheels in your home workshop. Let’s give it a try!
1/16" balsa wheel blanks and wheel plan outline
The RC plane plan spoke wheels concept involves building a tire rim from two layers of 1/16” balsa, with the wood grain of the two rims set at 90 degrees to each other. Setting the wood grain at 90 degrees is a CRUCIAL step for the light weight and strength of you RC plane plan spoke wheels. A simple, removable jig of 1/8” balsa is inserted across the diameter of the wheel rim, holding the brass tube axle in place. Thread spokes are installed. Once the initial RC plane plan spoke wheels thread is in place, the temporary jig holding the axle in place is cut out and removed, hence the term “lost jig”. The remaining thread spokes are glued in place at the axle ends and on the balsa wheel rim. Neoprene fuel tubing is glued to the balsa rim, and your RC plane plan spoke wheels are complete.
Two 1/16" balsa spoke wheel blanks - glue cross grain for strength
Let’s now go through the RC plane plan spoke wheels building process in more detail. The first step is to cut out two wheel rims from 1/16” balsa. Use a medium to hard grade balsa for strength on this part of the RC plane plan spoke wheels. Use whatever diameter wheel your model requires. The width of the RC plane plan spoke wheels rim depends on what you desire for the overall look of the finished wheel. I recommend at least ¼” rim width to maintain wheel strength.
Use a sharp razor blade to cut these two RC plane plan spoke wheels rims out of the 1/16” balsa, as the circular wheel shape can break easily at the grain. Once the two RC plane plan spoke wheels rims are cut out, CA glue the two rims together with the wood grain 90 degrees apart for strength. The RC plane plan spoke wheels rim made from these two 1/16” balsa pieces is surprisingly strong. Now is the time, before any spokes are installed, to apply whatever finish or paint you desire for the wheel rims. Mark the spoke locations on the top of the wheel rim, which will be used for a guide as the thread spokes are woven into place. The RC plane plan spoke wheels marks will be covered later by the rubber tube tire.
1/16" balsa spoke wheel blanks glued together and wood stain applied; axle jig and axle tube at right
Next, build the temporary jig that will hold the axle in place as the RC plane plan spoke wheels thread is installed. Use a soft 1/8” balsa for this temporary jig. Soft wood is important, as you will have to carefully cut the jig out after the first set of spokes are installed. It is very important that this jig hold the brass tube axle firmly in place as the thread spokes are installed, so add some ¼” balsa fill on the jig for lateral support where the axle will be installed. Trim the ends of the jig to fit snugly in place inside the RC plane plan spoke wheels rim, and hold the jig in place with pins. Do not glue the jig to the wheel rim, as you will be removing the entire jig shortly.
Spoke wheel axle jig pinned in place with eight thread spokes
Drill a hole in the exact center of the jig for the brass tube axle. Drill the hole slightly undersize from your axle, to ensure a firm press fit. Insert the brass tube axle into the jig. Make two 1/16” plywood washers, and glue the washers onto the ends of the brass axle. These spoke wheels washers will retain the thread spokes at the axle ends as you weave the spokes in place.
Now for the fun part, actually installing thread spokes. Use whatever size and color thread you wish for the RC plane plan spoke wheels. Start by tying the thread to one end of the brass tube axle. Weave the thread over the balsa wheel rim, and back to the opposite end of the axle outside the plywood washer. Continue this application of the thread on alternating sides of the wheel. When you have around eight thread wheel spokes in place, tie off the thread at an axle end. Use a bit of CA glue to hold the thread in place at the axle ends and on top of the balsa wheel rim. This will not be the complete RC plane plan spoke wheels installation, as we need to allow room between the thread spokes to remove the jig. However, there are enough spokes to hold the axle in place.
Carefully cut out axle jig, then add additional thread spokes
Remove the pins holding the jig in place to the balsa wheel rim. Carefully cut out the jig from around the axle, taking care not to accidentally cut any of the thread spokes. Once the jig is completely removed, you can see the beginning of the RC plane plan spoke wheels. Add additional thread wheel spokes as you did before, until you have the desired look for your finished wheel.
Glue on neoprene tubing for spoke wheel tires
We are almost done. Use thick CA glue to install neoprene fuel tubing onto the outside of the balsa rims to simulate the spoke wheel’s rubber tires. Cut the tubing slightly long. Glue the tubing on to the wheel, leaving the last inch unglued. Once dry, trim the tube to fit, and glue the final length of tube on top of the wheel rim. If you cannot find black colored tubing, use a Sharpie black marker pen to color the tube before gluing to the rim.
Finished RC plane spoke wheels
That’s all there is to making your own RC airplane plan spoke wheels. The method allows for RC plane plan spoke wheels of just about any size. Go ahead and give it a try. The “lost jig” spoke wheel method is a fun, easy and inexpensive way to add character to your next antique indoor RC model airplane. This is also a great way to highlight the early days of model airplane flight as you can see in the radio control plane primer.