Just starting to get back to work on the charger as I've been very busy at work. I did put some time in on the steering wheel project and I'm happy with my progress so far. I found another steering wheel with good chrome on the spokes. And I decided to leave small 1" sections of the original plastic wood grain in place to help position the outer ring as well as locate the inner ring that I made smaller in diameter. My plan was to use a product called West System which is a two-part epoxy that has a variety of fillers to help color, thicken, and add strength. I started by making a small mold of the shape I was looking for and just move it around using plumbers putty too damn up the ends when I filled it with a epoxy. This worked OK but didn't give me the results I was looking for so I decided to make a full mold. After using it to make the top half of the steering wheel I modified it to clear the spokes and used it again for the bottom half of the steering wheel. This worked great and other than a few air pockets which I can fill-in along with the holes that I drilled so I could use a syringe to inject epoxy into the bottom of the mold I think it turned out great. I plan on making it a darker shade of brown and then comes the tedious part of replicating the wood grain.
Thanks
Pat
This is a picture of the partial mold that I started using
Here's the mold has been waxed and filled with epoxy
First pull of the new mold
Then I cut the mold to clear the spokes and flip the steering wheel to redo the shape on the backside of the steering wheel.
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