Well, I bought some wheels really cheap, and like most cheap things they're not really suited for my car. The center bore is 56.1, the Jetta I want to put them on is a 57.1 - so like, what to do? I guess 3d print a guide to precisely open it up without any specialized tools! Or that's what I'm hoping I'll be doing.
Clever!
That should hold you to "close enough" tolerance. It's not as if you need to be accurate to a thou there. Let us know how the finished product turns out!
Maybe print a couple in successively larger diameters? That router bit isn't going to like taking that much off in aluminum at one go...
I think I would have at least two flush-mount bolts to ensure the jig doesn't jump up for whatever reason
In reply to Kendall Frederick :
Lol, Agreed! I was in process of doing that, the first one was a bit looser on the tolerances than I liked!
In reply to Mr_Asa :
The pins into the studs are oversized actually, it's a VERY snug fit. I have to pry/hammer it out of the wheels.
In reply to brandonsmash :
I'll keep you guys updated!
Kendall Frederick said:Maybe print a couple in successively larger diameters? That router bit isn't going to like taking that much off in aluminum at one go...
Use gear oil for lube and the aluminum will cut like butter, unless the wheels have a righteous heat treat, then it will go less well.
One way to find out!
In reply to Pete. (l33t FS) :
Copy that!
I guess we'll find out together 
Cool idea!
This is true GRM mentality
LOVE IT, cool adoption of tech to help you adapt these to your VW
Kendall Frederick said:Maybe print a couple in successively larger diameters? That router bit isn't going to like taking that much off in aluminum at one go...
And that picture makes it look worse than it is, I'm only taking off .5mm all the way around to take out 1mm total!
I'm hoping a lubed up bit and slow moving means we survive the ordeal and don't test the safety glasses.
Carbide woodworking tools work fine in aluminum, have routered many wheel centers with a flush cut bit and a bearing
Boy do they
Well, it cut through it like butter BUT make sure you don't go counter clockwise, even for a millisecond... Ask me how I know.
No real damage to the bore or wheel (or me) but it TOOK off. Lesson learned.
The guy I got them from came with 5 wheels and 1 off road tire and now I'm thinking I need to get some chonky tires for the 500 dollar Jetta...
Really impressed with how the bore looks, very smooth
Nicely done! That's a clever concept that looks to be well-executed.
Have you driven on the wheels yet? I assume concentricity is not a problem?
In reply to brandonsmash :
Thanks! No problems detectable, they seemed more true than the abused steel wheels that came off of it. They're smoother going down the road too.
Well done! I keep seeing more and more stuff that makes me want a 3D printer.
In reply to Kendall Frederick :
My 3d printer isn't particularly nice (it's not bad either, but nothing special), I've seen the same type like new on Facebook marketplace for about 75 bucks!
Now, the learning curve wasn't fun, but it isn't as steep as it once was.
i've used hole saw to open pilots on lug-centric wheels before. this is a bit cleaner.
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