Eurofighter Wheels Freewing 90mm EDF

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Summary

Scale wheel rims for the Freewing Eurofignter 90mm EDF. Designed for use with Dave Brown Lite Flite low bounce tires (Mains 2.75", Front 2.0"). Dave Brown Lite Flite Treaded tires. The tires are low bounce, low noise and light weight compared to other low bounce tires. They reduce shock to the landing gear which improves durability on rough runways or when you are less than perfect.

Overview

Replace the OEM wheels with scale printed rims and low bounce tires. Coloration of main rims is accomplished in the print design with separate components using black & white filament.

Tire ODs measure ~68mm Main, ~50mm Front vs OEM 69mm & 49mm.

Tire widths measure 19mm Main & 19mm Front vs OEM 20mm & 15mm

Overall weight of the 3 wheel set printed in ASA is same as OEM at ~60grams (~2.1oz) rims & tires.

Bill of material

1. Printed Main Rim Set 2.75 G15.STL (or .3MF)
2. Printed Front Rim Set 2.0 22 G13.STL (or .3MF)
3. Main tires - Dave Brown (DB) Lite Flite 2.75" - 1 pair (WH27-5527 ~$9/pair)
4. Front Tire - Dave Brown Lite Flite 2.0" - 1 tire (WH20-5520 ~$7/pair)
5. OEM* 4x7x2mm bearings - quantity 4
6. Clear Gorilla Glue (non-foaming) or similar ductile adhesive compatible with filament selection

*Use the bearings which came with the model. Replacement bearings can be purchased at AliExpress or eBay

Recommended Tools

1. Die Tool Set 2.75 s.STL
2. Clamp Aids.STL
3. 9mm OD carbon fiber tube 180mm or longer
4. Cordless electric drill
5. Drill bits 2.2, 4.0 & 4.1mm - sharp and in good condition
6. Clamps
7. Deburr tools for 3D printed parts
8. Toothpicks to spread glue

Build Steps

Print the needed .STL/.3MF files and deburr. Pay close attention to the ing surfaces of mating printed parts. The hex keys form a tapered t intended to snap in place during fitup. Clean up any print irregularities to ensure the fits work as intended for installation and removal of mating components.

Main Wheels

Remove the wheel rims from the Dave Brown 2.75" tires. Grab the edges of the rims and pull apart with a slight twisting motion. With the rims removed, it is recommended to allow the foam tires to relax before cutting the tire ID. Set the tires aside to relax for 1 to 7 days at ambient temperature.

Cut a larger ID on the main tire to fit the printed rims. Assemble Die Tool Set 2.75 s.STL on the 9mm carbon fiber (CF) tube with tire between die cutters. All 3 tools cut the same diameter so any pair will work. Use light compressive pressure on the dies to the tire. Rotate or rock the dies against both sides of the tire to produce frictional cutting of the tire. Repeat rotation, alternating sides to produce similar cutting depths on each side of the tire. Periodically retract the dies and inspect the cutting edge and the progress of the cut in the tire. After the cut is established ~4mm deep, cutting pressure may be increased to moderate. When the cut is completely thru the tire, remove the core. Inspect the die teeth prior to cutting the 2nd tire and replace as necessary if damaged.

Assemble the rims and drill the axle bores without the tires. Press the hex key into 1 of the rim halves. Align the printed timing marks on the rims and press the 2nd rim half onto the hex key until the rims in the center.

Precision drill the center bore to fit the axle into the wheel assembly. I used an electric hand drill at a very low speed (~30 rpm or less). Start with 4.0mm and then repeat with 4.1mm bit to get the final diameter. Clearing the plastic from the flutes of the drill bit after each use improves the quality of the successive hole in thermoplastics. Test fit OEM axle from the plane without the rolling element bearings. It should rotate freely with ease.

Separate the printed rim halves with a gentile rocking motion. With a fine point Sharpie, mark the timing line from the hex to the rim OD on both sides. It does not matter which side retains the hex key. Use different colors to keep track of the right and left wheels so they can be reassembled same as when they were drilled.

Test fit the wheel cover in the outer rim halve. The fit should be easy with light pressure. Check for uniform fit to rim. Test fit both bearings and the OEM axle. They should slide in easily similar to the OEM rims. Remove the wheel cover and bearings. The blunt side of a 2.2mm drill bit can remove wheel covers via the 3 holes in the outer rim. The axle can be used to remove the bearings.

Install the rims to the tires. Do not install the rolling element bearings for this step. Apply a thin uniform coat of adhesive to all of rim to rim ing surfaces. I did not glue the tire to the rims. Insert the rim with the hex key into the tire. Align other rim to the 1st rim with the timing marks and press the 2 together. The rim center lines should touch. Similarly apply a thin uniform coat of adhesive to the mating faces of the outer rim and the wheel cap. Clamp the rims together with the Clamp Aids.STL and allow the adhesive to cure. Be careful to not allow glue to the bearing counterbores or the Clamp Aids.

Remove the clamps. Chase the axle bore with the 4.1mm drill bit. Test fit OEM axle from the plane. It should rotate freely with ease. Install the OEM bearings. Measure the length of the axle protrusion on the inside of the wheel and compare to the OEM length. They should be very similar.

Front Wheel

The Dave Brown (DB) tire is wider that the OEM, but no modification is necessary. It fits well and looks more scale. Remove the wheel rims from the Dave Brown tires. Grab the edges of the rims and pull apart with a slight twisting motion.

Assembly of the printed rim and tire. Apply a thin uniform coat of adhesive to all of rim to rim ing surfaces. I didn't glue the tire to the rims. Insert the larger cylinder OD rim into the tire. Align the smaller cylinder OD rim into the 1st rim and press the 2 together. The rim will compress the tire so a clamp is required. Clamp the rim together with the Clamp Aids and allow the adhesive to cure.

Remove the clamp. Precision drill the center bore to fit the axle into the wheel assembly. I used an electric hand drill at a very low speed (~30 rpm or less). Start with 4.0mm and then repeat with 4.1mm bit to get the final diameter. Clearing the plastic from the flutes of the drill bit after each use improves the quality of the successive hole in thermoplastics. Test fit OEM axle from the plane. It should rotate with ease. Measure the length of the axle protrusion and compare to the OEM length.

The hub is asymmetric. The longer side faces toward the nose gear strut. Install the wheel in same fashion as the OEM wheels.

Installation

Install the wheel in same fashion as the OEM wheels.

the tire ODs are round & concentric to the center hole. Adjust as needed by pulling/pushing the tire. It need not be perfectly round. Runout of a few millimeters is adequate.

3D printing
- ASA filament used as shown, but others may also be suitable
- required on some components