Wagon wheel repair

Darren Wright

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Springfield, Missouri
My nephew took a job repairing some old wooden wagon wheels for his neighbor. Overall the wheels were in good shape, but had 3 broken spokes and part of one wheel that needed replacing that was dry-rotted.

For the wheel replacement, I had him save the outer cut-off to use as a support on the drill press when he got ready to re-drill the holes for the spokes.
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I saw in one of the wood magazines a while back how to do the round tenons on squared/rectangular wood using a jig on the router. The spokes on the small end were 1" across the diagonal, so we drilled a 1" hole to spin them in. Drilled a 5/8" hole on the bottom side where the router bit would be raised into the jig.

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Basically he just had to spin the spoke around and around until it bottomed out against the fence, worked like a charm.

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Yeah, I would used this one again, would be good for doing tenons on chairs. His first spoke was a bit tight and I told him to sand the edges a bit to loosen it for spinning it in the jig. He took off a bit more than I expected and it was a bit sloppy, but since he's drilling new holes he can sand it down to a smaller size and drill a smaller hole for that one...that or use lots of glue. ;)
 
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