Hi All,
This is a situation where redesign of the wheel is the easiest expedient. Toyota did this on the Prius wheels. They put a groove in the ID of the wheel. There is an expanding steel wire ring that the cap (called trim rings on a Prius) that pushes some a portion of the trim ring molding into the grooves. When I did my caps, all I had to do was cover the trim (polystyrene with steel wire ring) rings which just snap back into those grooves on the wheels. This simple, elegent design is very effective, and adds no cost to the wheel, just a different casting tool. Of course the trim-ring is extra money.
On an existing wheel, maybe a piece of plastic with a groove in it could be glued into the ID of the wheel, that something on the cap could snap into.
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