RFQ: Keyslot milling in alu round stock.

[mekanik]

Hi Adrian
As no one else has responded i will try and help, i would make these from mild steel. make outer rim inside bore to size, leave a tad on the OD for a final skim to size. machine the centre boss OD to size ID slightly undersize, again to skim after assembly, also machine a spigot to locate the disc portion, machine disc to fit inside the rim and locate on the spigot on the boss. manufacture alignment jig to align the ribs(aluminium ring with 5 radial slots) next bit depends on your equipment, ideally assemble components and using TIG on lowest amps fuse the webs to the rim & centre boss, remove jig flux assembly and silver solder, soak in water overnight to remove flux, machine a spindle assembly to hold wheel via the boss, set in 4 jaw chuck skim OD to final size, re-chuck & finish the bore and skim the front face. simples
Of course if you don't have a lathe u is fu**ed. but i assume you is a model maker so probably do.
Regards
Mike