Looking for ways to precisely cut apart 3 piece aluminum car wheels

I've read through the replies to your question which brings up more questions and a lot more questions to the suggestions. From a safety standpoint are you modifying the wheels for yourself or a customer. Liability,,,liability,,,liability! You're safety and wellbeing are important too. Taking the wheels apart isn't the difficult piece in all this. Reassembly is the more difficult task. I'm strong on the welding aspect of this and short on the maching side. 1). Taking the wheel apart can be done with abrasive wheels. There are plenty available designed for aluminum that don't load up and cut fast. 2) The safety factor of magnesium vs aluminum comes into play when you create dust and chips. Magnesium dust and chips create a fire hazard as already stated. It would be best to determine what you're working with before you start the process. 3). Moving past the machining portion of this and on to welding. If the wheels are magnesium they can be welded but are the new pieces aluminum or magnesium. You can't weld the two together. **Again, know what you're working with**. Based on the photos, the original welds were machine/automatic and the other (let's not call it a weld) was done by hand.

Based on your questions, I'm guessing you wish to do this by the most inexpensive method. Google welding magnesium, and there are quite a few links and a couple that have simple tests to determine the material you are working with. This would be a good place to start. If the wheels are aluminum, what's the alloy? You can get into trouble welding the wheels with the wrong filler metal. I'm guessing the wheels are aluminum base on the restrictions and hazards aof working with magnesium but the geographic location of the OEM does make a difference. Most wheel manufacturers have filler metals designed to match the alloy of the wheel and the assembly is done using the GMAW "Mig" process, but finding a match at your local welding supply house could be difficult. There are a few filler metal alloys suited for general purpose welding that will cover a range of alloys.

I think the probability of finding a machine shop to turn the pieces after you take the wheel apart would be easier and less expensive than finding someone with a 5-axis waterjet and the tooling to mount your wheels.

PS. Yes you can weld aluminum and magnesium together but the marriage will be annuled before the ink dries on the license.

Nothing is impossible, that of course does not imply that the result will be good.

Cutting the old wheel up is really quite simple first remove the bulk of the original rim with a bandsaw, then using a lathe machine the inner web to the final size making sure it is running true to the hub that you have.

The real tricky part is the welding it back together, First, are the respective aluminium alloys of the two parts the same alloy? If they are not you will need the advice of an expert in welding aluminium, even if they are the same, you would still be advised to consult an expert, structural welding is not for the amateurs. And aluminium is less forgiving than steel. The wheels after welding will most likely need heat treating if they are ever to be used on the road.

You would also do well to find out the relevant regulations in Japan for welding of wheels, and also home made wheels. Might be a can of worms right there.

Can it be done? Yes.
Would I advise it? No.

If this isn't done right it could be very fatal.

I suspect the skills required are well outside your own, so be smart and pay an expert or two and get the job done right. Find something else to satisfy your" look what I made gene."

Cutting it is the easy part. How do you plan on making the new rim with the bead?

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WreckWreck said:

A Vertical Turrett Lathe would make short work of that such as those produced by Bullard. Since you are not planning on running parts longer then automotive wheels, (long shafting for example), they take up far less floor space then an engine lathe of appropriate size, also they are easier to load.
They have many uses in turning large diameter short parts so I suspect that there are Japanese companies that produced them as well.
https://s-media-cache-ak0.pinimg.com/564x/f4/73/f6/f473f6aca9cb07107881e538e6b8ff2e.jpg

Click to expand...

A VT Lathe is ideal for this job.


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This is a bit out of the box, but I'm envisioning a custom made arbor to support a cold saw blade on a milling machine and using a larger rotary table to rotate the wheel.
Cold saw blades require slow RPM's (120 rpm and under) . As mentioned, a lathe would have to be rather large for this operation. A flood coolant would also be needed. I don't think cutting the Aluminum with the correct blade would be a issue taking small bites. You might even be able to use a quality carbide tooth circular saw blade with this set up.
As for welding, a decent welding positioner and a quality spool gun would work (lots of practice).

Not calling you out on your abilities, but please understand the hazards others have mentioned when reworking wheels.
I'm with brino, in terms of trying new things and "going for it", just be safe. Not only does your life depend on a quality modification but others you share the road with.

Thank you guys for all of your great responses. I appreciate the advice and ideas you've come up with and will take your advice into account when making my decisions on how to cut the wheels apart.

In my searches, in Japanese, I have come across a few people who do the work I want to get done and was able to visit with one of them and see how he does it. Unfortunately, he refuses to just cut apart wheels for me since the process of cutting, attaching new outer barrels, welding (some of which he outsources) is his business and he charges nearly 1000 USD per rim to do it.

http://ameblo.jp/vats4649/entry-12129570992.html

I have attached a picture of the lathe he is using.