Fuel Economy, Hypermiling, EcoModding News and Forum - EcoModder.com - WesternStarSCR's Album: Smooth Wheel Covers
This thread will document my materials and steps to add aluminum pizza pans my 2004 Chevy Malibu Maxx LT with 16 inch stock wheels.
WARNING: I plan on drilling 5 very small holes directly through each wheel for #8-32 tapped screws. I make no assumption as to the suitability of doing the same to your own wheels. I know the size and thickness of my wheels, and I have ZERO saftey concerns with this process. Proceed at your own comfort level.
I will edit this post as I go. I will keep the Bill of Material (BOM) as straighforward as possible, using item numbers from the store where purchased from.
Why do this?
http://ecomodder.com/forum/showthrea...html#post63787
How to do this?:
65+ Vehicle modifications for better fuel economy - EcoModder.com
http://ecomodder.com/forum/showthrea...ers-23563.html
http://ecomodder.com/forum/showthrea...orn-14306.html
Reasons for my own variation:
I liked the concept of a semi-permanent stud that 'raylit20' came up with in his solution. However, I did not want the concern of perhaps having to take off the center plastic cap at some point for a mounting or balancing machine at a tire store. I would also not be confident in my own epoxying abilities to have just one point of failure.
So, 'NachttRitter' used the acorn caps of the lugnuts themselves, to have multiple attachement points. However, it seemed that I would have to purchase different lug nuts to try this one. Also, I tought it best to have the studs mounted on the wheels, so that when it is re-balanced, the weight is already there. Making the bolts be the part that comes off means they are not on the wheel during balancing.
Summary of my Plan:
1. Studs
Use Stainless Steel #8-32 Machine Screws.
Drill #29 pilot hole in each wheel at each spoke, in the groove that is already in the design.
Tap from the back side with an 8 - 32 tap.
Insert screw, with external lock washer, from behind with some blue Loctite.
2. Discs
Use 17" Aluminum Pizza pans (proper size for 16" wheels)
Drill 5 holes for rubber grommets, lined up with studs.
Drill a 6th hole to a larger grommet, to protect the air valve & extension
Insert grommets into the holes on pizza pan.
Use nylon retaining washers and SS fender washers on both sides, put disc onto studs.
Secure with hex lock nut using 11/32" socket (correct for #8 size nut).
Put 11/32" combo wrench in glove box so that they can be removed during a tire change.
BOM:
Most items came from Grainger (you need a business account with them, or may may find a retail source for similar item)
Slime brand metal Air Valve extensions -
Auto Zone
#8-32 SS Pan Head Phillips Machine Screws (2" LONG) -
Lowes
SS Lock washers-
Lowes
17" Aluminum Pizza Pans -
Grainger - Item # 20W867
Nylon Retaining Washers -
Grainger - Item # 3XYX9
SS Fender Washers -
Grainger - Item # 4ARR3
SS Lock nuts -
Grainger - Item # 3PDG1
Weather resistant grommets for stud holes -
Grainger - Item # 3MRP7
Weather resistant grommets for air valve holes -
Grainger - Item # 3MRT1
Build Log:
11-10-2012 - Began acquiring material
11-13-2012 - Began this thread
11-14-2012 - Found pictures on internet to mark up location
11-15-2012 - Changed idea from thru hole w/ locknut to a tapped hole.
05-1402013 - Began Mocking up the stud assembly