# Sovereignty Module: Rim the Wheel

## Complete Wagon Tire and Wheel Hardware: From Bar to Rolling Stock

Wagon wheels require precision ironwork for durability and strength. This campaign covers tire making, hub bands, axle hardware, and wheel assembly.

### Chapter 1: Wagon Wheel Components

| Component | Material | Purpose | Difficulty |
|---|---|---|---|
| Tire (iron rim) | 1/4 x 1.5-2 inch flat bar | Protect wooden rim, hold wheel together | High |
| Hub bands | 1/8 x 1 inch flat bar | Reinforce hub, prevent splitting | Moderate |
| Linchpin | 3/8 inch round | Hold wheel on axle | Low |
| Axle box (bearing) | Cast iron or forged | Bearing surface for axle | High |
| Spoke plates | 1/8 inch plate | Reinforce spoke-to-hub joint | Moderate |
| Axle strap | 1/4 x 2 inch flat bar | Hold axle to frame | Moderate |

### Chapter 2: Tire Making

Tire making process: 1) Measure wheel circumference precisely (wrap string around rim). 2) Cut flat bar to circumference minus 1/4-3/8 inch (shrink allowance). 3) Heat bar ends and forge weld into ring. 4) True the ring (make perfectly round using mandrel or jig). 5) Build tire fire: large circular fire pit. 6) Heat tire in fire until uniformly red-hot (expand from heat). 7) Quickly place hot tire over wooden wheel rim. 8) Tire expands when hot, fits over rim. 9) Immediately quench with water (buckets, hose, or dunk tank). 10) Tire contracts as it cools, gripping rim tightly. 11) Shrink-fit pulls all joints tight (spokes, rim, hub). 12) The tire holds the entire wheel together.

| Specification | Small Wheel (30 inch) | Medium Wheel (42 inch) | Large Wheel (54 inch) |
|---|---|---|---|
| Tire circumference | ~94 inches | ~132 inches | ~170 inches |
| Tire width | 1.5 inches | 1.5-2 inches | 2-2.5 inches |
| Tire thickness | 1/4 inch | 1/4-5/16 inch | 5/16-3/8 inch |
| Shrink allowance | 1/4 inch | 5/16 inch | 3/8 inch |
| Weight | 8-12 lbs | 15-20 lbs | 25-35 lbs |

### Chapter 3: Tire Setting

| Step | Action | Critical Factor |
|---|---|---|
| Measure | Wrap string around rim, mark | Accuracy determines fit |
| Cut bar | Cut to circumference minus shrink | Too short = won't fit; too long = loose |
| Weld ring | Forge weld ends together | Clean, strong weld (no cold shuts) |
| True ring | Make perfectly round | Out-of-round tire damages wheel |
| Heat tire | Uniform red heat in tire fire | Uneven heat = uneven expansion |
| Set tire | Place hot tire on wheel quickly | Speed is critical (tire cools fast) |
| Quench | Drench with water immediately | Rapid cooling = tight shrink fit |
| Check | Verify tire is tight all around | Loose spots need re-setting |

### Chapter 4: Hub Bands and Hardware

Hub band installation: 1) Measure hub diameter at each band location. 2) Cut flat bar to circumference minus 1/8 inch. 3) Bend into ring, rivet or weld closed. 4) Heat band to red, drive onto hub. 5) Quench to shrink-fit. 6) Typical wheel has 2-3 hub bands. 7) Bands prevent hub from splitting under spoke pressure.

| Hardware | Purpose | Installation |
|---|---|---|
| Hub bands (2-3) | Prevent hub splitting | Shrink-fit (same as tire) |
| Linchpin | Retain wheel on axle | Insert through axle end hole |
| Axle washer | Reduce friction, prevent wear | Between hub and linchpin |
| Spoke plates | Reinforce spoke mortises | Riveted to hub face |
| Axle clip | Backup retention | Clip on axle end |

### Chapter 5: Axle Hardware

| Component | Stock | Purpose | Specification |
|---|---|---|---|
| Axle strap | 1/4 x 2 inch flat | Hold axle to bolster/frame | U-shaped, bolted through frame |
| King pin | 3/4-1 inch round | Connect front axle to frame (pivot) | Allows steering |
| Reach plate | 1/4 inch plate | Reinforce reach-to-axle connection | Bolted or riveted |
| Brake hardware | Various | Slow or stop wagon | Lever, linkage, brake shoes |
| Fifth wheel | Forged ring assembly | Steering pivot for front axle | Two rings, one on axle, one on frame |

### Reference Card

1. The tire holds the wheel together (the iron tire is heated to expand, placed over the wooden rim, and quenched to contract; this shrink-fit pulls every joint in the wheel tight and holds the entire assembly together). 2. Measure twice, cut once (the tire circumference must be precisely calculated; too short and it cannot be set; too long and it will be loose; accuracy to 1/8 inch is required). 3. Speed is critical during tire setting (the hot tire must be placed on the wheel and quenched within seconds; a slow set allows the tire to char the wood before it can be cooled). 4. The forge weld must be perfect (a weak weld in the tire will fail under the stress of shrink-fitting; the weld must be as strong as the parent metal). 5. Hub bands prevent splitting (the hub is under enormous stress from the spokes pushing outward; hub bands compress the hub and prevent it from splitting along the grain). 6. The linchpin retains the wheel (a simple pin through the axle end prevents the wheel from sliding off; losing a linchpin means losing a wheel). 7. Tire setting requires a team (one person cannot set a tire alone; heating, lifting, placing, and quenching require 2-4 people working in coordination). 8. A wheelwright and blacksmith work together (the wheelwright builds the wooden wheel; the blacksmith makes and sets the iron hardware; together they produce one of the most important technologies in human history).