This project uses a 12mm or 1/2” thick aluminum plate or round bar to create a hand wheel.
If using cutoff round bar material you may need to square it up in the lathe first. Drill through the center of the material with a 5.0mm drill and thread with an M6 (6mm) tap. This serves to bolt the aluminum to a piece of material that can then be clamped to the machine bed.
When complete the center hole can be drilled or reamed out to the size required. The file's provided will machine the basic shape, other details can be done manually to one’s own requirements.
http://www.mycncuk.com/images/dump/handwheel3d.gif
http://www.mycncuk.com/images/dump/handwheelA3d.gif
The G-Code file to machine basic wheel shape using a 4mm slot drill and a pdf of the part are attached to this post below. The part is quite a large file and may take a couple of hours to complete, if a lathe is available you could also turn the wheel for a final finish.
This was originally provided by Roy over at www.diycnc.co.uk, He also has some other cool projects too.