Making your own "smooth" wheel covers
 

OK so I got the inspiration for this from http://ecomodder.com/forum/showthrea...vex-14958.html. And while I posted this there, I figured it warranted it's own post here as well. Hopefully this is step by step enough that anyone can follow and do this.

Parts:
Wheel Covers
Fiberglass resin
T-shirts x 4
Mixing Bucket
Acetone

Tools:
Mixing Stick
Paintbrush
Razor knife
Dikes

Ok, so I bought my wheel covers on ebay for a total of $15.
http://i172.photobucket.com/albums/w...h_100_1073.jpg
I went to Lowes and my local auto parts store for the needed Supplies. I got the Fiberglass Resin at the auto parts store for about $12. It was about $12 for the bucket, paintbrush, and acetone at Lowes.
http://i172.photobucket.com/albums/w...h_100_1074.jpg
Something I didn't take a picture of was the actual sanding of the wheel covers, but I took a 150 grit foam sanding block to rough up the surface a bit to help make sure the resin would stick. Here's a pic of the after. Also make sure to clean off the dust with a damp rag.
http://i172.photobucket.com/albums/w...h_100_1075.jpg
Instead of using t-shirts I had, I went to goodwill and bought 4 from their $.99 rack. Here is one of the ones that I got.
http://i172.photobucket.com/albums/w...h_100_1076.jpg
Make sure to not use shirts that you like because this is how they will end up
http://i172.photobucket.com/albums/w...h_100_1117.jpghttp://i172.photobucket.com/albums/w...h_100_1118.jpg
Ok, start by putting the wheel covers in the t-shirt facing the side with no printing on it. ( I say this because I don't think the resin will soak through the screen printing.)
http://i172.photobucket.com/albums/w...h_100_1077.jpg
Make sure to position it so that all the holes can be gathered easily into the center.
http://i172.photobucket.com/albums/w...h_100_1078.jpg
Ok, now install the tension ring
http://i172.photobucket.com/albums/w...h_100_1079.jpg
The next step is to carefully pull the shirt as tight as you can. Gotta be careful that you don't either tear the shirt or break the cover.
http://i172.photobucket.com/albums/w...h_100_1080.jpg
This next part is kinda difficult at first. Take all the loose t-shirt gather it up nice and tight and put either 1 or 2 zip ties around it depending on the length of your zip ties.
http://i172.photobucket.com/albums/w...h_100_1081.jpg
You want to get this pulled around the wheel cover as tight as you can this is what will help you get a nice smooth surface on the other side. I set it on a bucket to make it easier to work on at this point.
http://i172.photobucket.com/albums/w...h_100_1085.jpghttp://i172.photobucket.com/albums/w...h_100_1087.jpg
Ok, Now for the smelly part. Mix the resin according to the instructions on the can. My instructions were to mix approx 1/4 of the hardner with approx 1/4 of the can. Just make sure to follow your instructions and mix well. Also remember to work quickly.
http://i172.photobucket.com/albums/w...h_100_1088.jpghttp://i172.photobucket.com/albums/w...h_100_1089.jpg
Now time to apply. I started in the center and worked my way out. just keep going and spreading until the shirt is saturated and you can kind of see the wheel cover through it. Make sure to get the edges well.
http://i172.photobucket.com/albums/w...h_100_1090.jpghttp://i172.photobucket.com/albums/w...h_100_1091.jpghttp://i172.photobucket.com/albums/w...h_100_1092.jpghttp://i172.photobucket.com/albums/w...h_100_1093.jpghttp://i172.photobucket.com/albums/w...h_100_1094.jpghttp://i172.photobucket.com/albums/w...h_100_1095.jpghttp://i172.photobucket.com/albums/w...h_100_1096.jpg
When you finish with the one, set it aside and move on, keep doing this until you have finished all 4.
http://i172.photobucket.com/albums/w...h_100_1097.jpg
Allow the resin to set and cure for however long it says on the container. Mine said 2 hours, but due to lack of lighting working outside I let mine sit until the next day. Once it has cured remove the tension rings.
http://i172.photobucket.com/albums/w...h_100_1099.jpg
Next take a pair of scissors and work your way around the edge cutting off the shirt.
http://i172.photobucket.com/albums/w...h_100_1100.jpghttp://i172.photobucket.com/albums/w...h_100_1105.jpghttp://i172.photobucket.com/albums/w...h_100_1107.jpg
This is what you end up with after removing the shirt.
http://i172.photobucket.com/albums/w...h_100_1109.jpghttp://i172.photobucket.com/albums/w...h_100_1110.jpghttp://i172.photobucket.com/albums/w...h_100_1111.jpg
Now go around the edge with a razor knife and trim off anything that you couldn't cut through with the scissors.
http://i172.photobucket.com/albums/w...h_100_1113.jpg
For especially thick drips you may need to use a pair of dikes.
http://i172.photobucket.com/albums/w...h_100_1114.jpghttp://i172.photobucket.com/albums/w...h_100_1115.jpghttp://i172.photobucket.com/albums/w...h_100_1116.jpg
So the kinda muddy brown of the hardened resin is kinda ugly so I grabbed a can of black spray paint I had lying around.
http://i172.photobucket.com/albums/w...h_100_1119.jpg
This is probably a good project for practicing your spray paint technique if you need too. I just did multiple passes until it was solid black then moved on. Don't forget to get the edges otherwise you'll have black covers with white (brownish) edges.
http://i172.photobucket.com/albums/w...h_100_1120.jpghttp://i172.photobucket.com/albums/w...h_100_1121.jpghttp://i172.photobucket.com/albums/w...h_100_1122.jpghttp://i172.photobucket.com/albums/w...h_100_1125.jpg
All four of them painted and waiting to dry.
http://i172.photobucket.com/albums/w...h_100_1126.jpg
Ok, that's it. you are now the proud owner of (mostly) smooth hubcaps.
http://i172.photobucket.com/albums/w...h_100_1129.jpg
If you want them absolutely smooth you could do multiple layers so you can have enough to be sanded. I don't mind the bit of texture.

And here are the before and after pics of my car.
http://i172.photobucket.com/albums/w...h_100_1127.jpghttp://i172.photobucket.com/albums/w...h_100_1128.jpghttp://i172.photobucket.com/albums/w...h_100_1131.jpghttp://i172.photobucket.com/albums/w...h_100_1132.jpg

nice!!!!

Perfect ! Well done. :)

I would suggest to try out how it forms out if you dry them out, up side down. That way the cloth wont touch the original cover and you should be able to get even smoother surface ;). Correct tension to the cloth is the key to the smoothest covers.

Neato! Reminds me of silk and dope covering of model airplanes.

My thought was using a different hub cap that doesnt have those peaks. But i doubt you'd see much more gain than from how he did it.

Good work. I hope they stick and don't fling off after some time in the sun. Possibly secure them with tiny screws for extra insurance. Just a thought.

Nice! If you check out the "kinda convex" thread on this, I just posted a few pictures of my Saturn OEM wheel covers that I did this trick on, only with a different approach. I made a plywood frame to stretch the cloth over, stapled it, put the resin to it, then placed it over the cover. This worked out very well for me (did two so far, the third one is curing right now), kept the material tight with a nice convex shape and little, if any sagging.

Yes no more fuel effiency gains but just little bit smoother looks. Anyway very nice covers already.

Is it ok to drive your car with the cover attach or do I need to remove the cover if I use my car?

They haven't come off yet. I curbed one and had to repaint it. Also had to superglue part of one back on after I took the whole cover off to do some car repairs.