Moon Discs , the how to, by Bob Ellis
Posted: Thu Jan 03, 2008 8:24 am
Bob Ellis ( DLRA #66) sent me this when I was asking Q's about attaching Moon discs , we ended up going another way which I'll explain elswhere but this is a good method....Ta for that Bob
The disc on the right is the template for everything.I indexed the setout,3 holes (1/16" Dia) 120degrees apart, 1 7/16" in from edge of disc.This template simply sits INSIDE of the new disc,drill thru the 1/16" pilot hole, then drill out to 7/16", ready for stamping.(will explain soon).
The template was also used to make the disc on the left, which is the template for welding on the fastener plates.Same deal,transfer the 1/16" pilot holes & drill to 7/16",(These holes DO NOT get stamped)
The cutouts are to tack weld plates to rim, I use part No's-DZUS1050 (Weld on plate-Lightweight), DZUS4050(Countersunk Button 0.500" Long),All from MSCN.com.au .
Now the trick bit! Take the welding template , rivot the dzus springs to the weld on plates (you may have to trim plates to fit in side rim) , insert dzus buttons thru disc, Place a 1/16" thick washer over button,between the template and the weldon plate , and lock the 3 plates on.Sit in rim , tack the plates thru the cutouts in template. (is a good idea to use antispatter on template , rim etc)Undo the dzus fasteners , remove template ,finish weld the plates to rim.Easy!!! Now back to the Moon discs.You have already got the 3x 7/16" holes , these need to be deburred.To stamp the countersink ,i used a 11/16" Nylok nut as the female die, and a dzus button as the male.sit the disc on the nut ,drop in the dzus button , line them all up , tap the dzus with a ballpein hammer , Done! I use Neil Stamp's discs ,and i had 2 old ones (from the welded nuts era) that i made the templates with.My indexing is out a touch , but every disc & rim has a mark on them, so that any disc can go on any rim.Hope this is of some help.
Cheers, Bob.
The disc on the right is the template for everything.I indexed the setout,3 holes (1/16" Dia) 120degrees apart, 1 7/16" in from edge of disc.This template simply sits INSIDE of the new disc,drill thru the 1/16" pilot hole, then drill out to 7/16", ready for stamping.(will explain soon).
The template was also used to make the disc on the left, which is the template for welding on the fastener plates.Same deal,transfer the 1/16" pilot holes & drill to 7/16",(These holes DO NOT get stamped)
The cutouts are to tack weld plates to rim, I use part No's-DZUS1050 (Weld on plate-Lightweight), DZUS4050(Countersunk Button 0.500" Long),All from MSCN.com.au .
Now the trick bit! Take the welding template , rivot the dzus springs to the weld on plates (you may have to trim plates to fit in side rim) , insert dzus buttons thru disc, Place a 1/16" thick washer over button,between the template and the weldon plate , and lock the 3 plates on.Sit in rim , tack the plates thru the cutouts in template. (is a good idea to use antispatter on template , rim etc)Undo the dzus fasteners , remove template ,finish weld the plates to rim.Easy!!! Now back to the Moon discs.You have already got the 3x 7/16" holes , these need to be deburred.To stamp the countersink ,i used a 11/16" Nylok nut as the female die, and a dzus button as the male.sit the disc on the nut ,drop in the dzus button , line them all up , tap the dzus with a ballpein hammer , Done! I use Neil Stamp's discs ,and i had 2 old ones (from the welded nuts era) that i made the templates with.My indexing is out a touch , but every disc & rim has a mark on them, so that any disc can go on any rim.Hope this is of some help.
Cheers, Bob.