This thread inspired me, so here is a short writeup of how I built my first disc wheel. The wheel is built with BHS SL210 hub, Sapim Lasers and a BHS c22w rim laced 16:8. Molds were cnc milled from Sikablock M700, sealed first with epoxy, then mold sealant and finally treated with release agent. The layup is (from the outside) one layer 160g/m2 spread tow fabric, 1.2mm airex with a particular cut pattern (see photo) and again a layer of 160g/m2 spread tow with four cutouts (about 15mm offset relative to the cutout in the foam so the inner fabric layer meets the outer). The covers were then glued to the rims with UHU Poly Max. There is almost no gap ( 0 to 0.5mm) between cover and brake track. Weight of the finished wheel is 1112g.
The wheel works fine but still has potential for improvement. Maybe avoid the four cutouts in the central part of foam and inner layer, in the section where there is only a single layer of fabric a carbon tow with superglue (on the inside) had to be added to avoid any flopping.
The wheel works fine but still has potential for improvement. Maybe avoid the four cutouts in the central part of foam and inner layer, in the section where there is only a single layer of fabric a carbon tow with superglue (on the inside) had to be added to avoid any flopping.