Dangerous alloys. - David W
I've a quickish smart car in today. New set of aftermarket alloys were fitted two years ago and the vehicle has done less than 10K since.

On the thorough inspection I always do, taking all the wheels off, I see three of the wheels have cracks radiating from the wheel stud holes. On one wheel these are serious enough in my opinion to cause the wheel to break away from the studs under enthusiastic use.

Cheap wheels, overtightened wheel nuts or both? I don't know but that is going to cost the owner a new set of alloys. I did notice these were made for, and fitted with, the same taper-seat nuts as steel wheels. I far prefer alloys that take the flat-seat nuts.

This is some confirmation that these services where the wheels aren't removed from one year to the next (or at very long intervals) are not good enough.

Now I've got to phone the bloke and tell him! Any pointers for some decent quality alloys at reasonable cost?

David
Re: Dangerous alloys. - Matt Kelly
www.bbsdirect.co.uk

Depends what size but the RZ look OK and seem a good deal with tyres attached.
Re: Dangerous alloys. - Trevor Potter
BBS are very good, but expensive.

OZ or FOX?

But NEVER "replicas" (tested and certified to WHAT standard)

checkout www.protyre.co.uk/
Re: Dangerous alloys. - John S
David

Do the wheels fit properly on the centre spigot? If they don't that's almost certainly the problem, as the loads are being taken only by the studs.

Always a point to watch for with after-market wheels.

However if they are OK in that area, then it's probably poor quality somewhere. Where the wheel nuts actually tight enough, by the way?

When you ring the owner, I trust he thanks you for spotting a potentialy lethal problem, despite the cost of rectification!

Regards

John
Re: Dangerous alloys. - David W
John,

Well there is an issue with the centre fit as well. I was amazed to see the fit was obtained with plastic adaptors so the "standard" oversize centre would fit the hub. Interestingly this adaptor had a part number and was the same brand as the wheels.

I see very few aftermarket alloys here so I'm not familiar with the dodges they get up to so one wheel may fit several cars.

Yes the wheel nuts were tight, too tight!

I'll have a browse around those sites and see what the replacements are going to cost.

As a matter of interest I had two LR Discoverys here one after the other a while back. One had LR OE alloys and they were works of art. The other had replicas and they did look chunky but the spokes were hollowed out at the back so the actual cross section of material carrying the rim was minimal.

Thanks

David
Re: Dangerous alloys. - Andy P
Almost all alloy wheels come with plastic hub rings so that one particular wheel can fit several cars. The BK Racing wheels I have on my Accord have them, as they're fine. One important point is that the standard wheel bolts (i.e. those used for the original steel wheels) should never be used for alloys. They have different shaped shoulders. If used, they inevitably cause damage to the bolt holes.


Andy
Re: Dangerous alloys. - John S
Andy

Vauxhalls supply their alloy wheel equipped cars with steel spare wheels and use the same bolts for both. Clearly they are designed that way.

The important thing is that the wheels and bolts are compatible.

Regards

John
Re: Dangerous alloys. - j.cronin
Ford say the same.You can use alloy wheel nuts on steel wheels but they look funny but you must NEVER use steel nuts on alloy wheels!!
Re: Dangerous alloys. - John S
David

I'd not be happy with plastic adaptors, as I would be concerned about their load carrying ability. However, from Andy's comment this must be standard practice.

Must come back to either:

Are the centre adaptors a good fit;
Quality of the wheels (type fault or this batch);
or the wheel nuts (type/fit, torque etc)

I'm asssuming you didn't do them this tight last time so how did they get like that? Original wheel fitting, replacement tyres or something?

How about a claim against the wheel suppliers?

regards

John
Re: Dangerous alloys. - KB
Maccess do a range of alloys at 'trade' cost, or perhaps Elite Tyres in Rainham, Essex or Micheldever in Winchester, who seem pretty cheap. Maybe Costco do alloys as well as tyres.


KB.
Re: Dangerous alloys. - Flat in Fifth
Remember when Revolutions came out?

Two types marketed, road type and competition type, the latter had much thicker spokes, greater load bearing surfaces and the nut/bolts/studs were longer of course.

Also I just don't trust these adaptor/spacer things.

The other thing is that it depends upon the grade of material used for the wheels themselves. Its been discussed here before but too often the alloys are fashion accessories, and are neither stronger nor lighter than the steelies.

Competition cars don't use magnesium as an example for nothing.

Also its possible to design in steel so that the stress is below the fatigue limit, not possible to do this in absolute terms in non ferrous alloys. But then I would say that wouldn't I.
Re: Dangerous alloys. - Richard Hall
The plastic centre bush is a bit of a red herring. I read an article by (I think) L J K Setright a few years ago, pointing out that the centre spigot doesn't carry any load, and that there is no shear load on the wheel bolts either. The load is transmitted through the friction between the axle hub and the wheel, and the purpose of the bolts is to clamp the two tightly together to maximise the friction. So the bolts are only subjected to tensile loads, and the only reason for the centre spigot is to centre the wheel before you do the bolts up. Many older cars don't have a centre spigot, and the wheels only fall off if you don't do the bolts up tight....
Re: Dangerous alloys. - David W
Richard,

I don't know but I couldn't dismiss the load bearing at the hub centre completely. I can't remember exactly but there is a problem with swapping alloys/wheels from different vehicles in the Land Rover range as some were designed for wheel centre load bearing and others for the studs to take it all.

If the centre isn't designed to share the load why do many wheels fit so closely to the hubs? As the wheel nuts/bolts have a tapered seat it should be possible to do away with the fit so tight they rust on....but they keep doing it.

David
Re: Dangerous alloys. - UKC32
That would have to be an LJKS article.
Re: Dangerous alloys. - John S
Richard

Are you a reader of 'Car'?

Oddly, I was recalling an article by the same gentleman, who was attempting to buy alloys for his Honda many years ago, and went to great efforts to get a set of wheels which accurately fitted the centre spigot! He was complaining about efforts to sell him wheels which sported a larger than required centre hole, thus leaving all location to the studs.

Yes, I agree that the wheel bolts should achieve sufficient clamping force to prevent movement of the wheels, and the centre spigot should only act as a centring device. The studs should not be a tight fit in the holes, but should be centred by the tapered seats of the nuts, and/or by the spigot. All these factors are important. Older cars probably survived because cornering forces and wheel loadings were somewhat lower.

Under cornering there is a degree of distortion of the wheel centre as the wheel is loaded. This is why poorly fitted hub caps usually disappear on corners.

Aluminium alloys behave differently under load than steel. They don't display a clear elastic limit, and even a high strength Al alloy has an Ultimate Tensile Strength well below even the elastic limit of a mid range steel. Size for size Al alloys exhibit greater deflection for a given load. In some ways not an ideal wheel material, and as has been mentioned, unless of high quality, unlikely to display any great weight saving. This all means that unless alloy wheels are properly designed the distortion in service will be greater than in the steel wheels. Because of the increase propensity for distortion, the clamping load of the wheel studs will be critical. No doubt recognising this, some carmakers specify a greater wheel bolt torque for alloy wheels compared to the steel wheels.

A properly sized wheel will have the close fit on the spigot, and this will tend to limit movement in this crucial area, should the design of the wheel be marginal causing excessive distortion of the wheel centre. This extra restraint will be absent if a plastic spacer is used, as this will only centre the wheel during installation. Therefore it's feasible that a combination of marginal wheel design combined with a lack of support at the spigot could lead to problems, and in any case the centre spigot provides some extra security if the wheels are subject to high loadings.

Regards

John
Dangerous driving kills off Minor wheel - Darcy Kitchin
John
I've posted before that many of my experiences with Morris Minors have been poor or scary. Here's one...
About 25 years ago I "borrowed" an elderly Minor from a chap at work for a month or two while I was "between" cars. Showing off one night with GF (now Madame) aboard, I came in to the pub car briskly and completely botched a handbrake turn. The car slid sideways into the kerb, the right front taking the brunt of my abuse. A loud metallic crack was heard, which I put down to the hubcap coming off.
Days later I was on my way to a job out of Leeds on the M621 when I was overtaken by a wheel.
"Some poor sod has lost a wheel" thought I, as the car settled onto the brake drum.
The wheel was retrieved with a roughly rectangular hole connecting the wheel nut holes and the corresponding piece was still attached to the drum by 4 nuts.
I put the spare on and bought another wheel and hub cap from a scrappie that weekend.
Just about on topic.
When I was a boy....... - David W
Kindred spirits Darcy.

Once lost a wheel from the rear of my Herald while flat out round a corner. I had wide tyres and those wheel spacers with stud extenders. The load was just too great and the threads stripped.

The wheel was the rear outer under load on a 40mph corner. Amazingly the brake drum and chassis hit the road with a bang but there was little change in cornering the line.

Bloke came out of his house nearby but I waved him away with a casual "OK mate, only the back wheel fallen off". Jacked it up, re-fitted the wheel and home with a bit more care until I fitted new wheel studs.

Long term resolution was to fit some 5.5Js made specifically for the car with 175 tyres and then I could lose the spacers.

With that 1147cc (?) engine you *really* needed big tyres.

David
Happy Days - John S
Darcy

Was that an early Minor (ie pre Minor 1000)? I believe for the 1000 the wheels were 'beefed up' including thicker material for the centres! Bit late to save face now, but it could be a partial explanation!

As for David, yes, we all remember wheel spacers. No self respecting boy racer was complete without a set, although most graduated to a set of 'proper' wide wheels. On the other hand there was a chap I knew who stuck for cash simply bolted the wheels on inside out. Luckily the overhang was so great he was forced to reverse this decision fairly rapidly.

My worst event was also when out with the 'GF, now wife' in my Mk1 Cortina. (originally a 1200 DL, I fitted the big valve 1500 GT engine, 3.77 lotus diff, lowered suspension, 5 1/2 J's, extra instruments etc. You get the picture) I'd been a bit concerned that one rear corner of the car was looking a little lower than usual, but you know what they say - if it don't scrape, it aint low!

Driving over a bump in the road, the said corner emitted a bit of a thump and settled on the bump stops. The leaf spring had broken, luckily just behind the axle. So, staggered home to GF's house at much reduced pace. Then there was the time the fuel line came of the carb on the motorway and showered the engine bay in fuel........

Happy Days

Regards

John
Re: Happy Days - Darcy Kitchin
John,

I'm not a Minor expert, but it didn't say "1000" on the bodywork anywhere. This was the car that I took from Leeds to Hull in a snowstorm and where I learned a little about management technique as follows;

Scene; offices in Seacroft, Leeds, complete white-out, 3 inches of snow on the ground. Australian hard-case manager enters.
Manager "Darcy, I need you to go to XXXX in Hull, right now, here's your fault report"
Me "But, Rufus, it's snowing"
Manager theatrically raises eyebrows and walks over to window and presses face against glass with some irony.
"Correct. Were you planning to drive home tonight?"
Me "Yes", thinking of the 4 mile journey to Leeds.
Manager "If you can drive home, you can drive to Hull. Now get going you lippy Pommie b*st*rd before I change my mind and swap this fault report for your P45"

And the Minor fish-tailed its way through the snow to Hull and back again.
Re: Happy Days - John S
Darcy

What we call a Graduate of the JFDI(*) School of Management

regards

john

(*) Just Flipping Do It (No, hang on, I don't think I have the second word correct. Umm......
PS - John S
If it didn't say 1000 on the bodywork, it was an early one. Gosh, nearly forgot the motoring link.
Re: Dangerous alloys - important note. - ian (cape town)
John S wrote:
> Aluminium alloys behave differently under load than steel.
> In
> some ways not an ideal wheel material, etc etc etc
Thanks for that, John S.
I feel this is a very important point, especially as there now seem to be a proliferation of alloy-wheel refurbishment places, specialising in fixing buckled wheels.
I don't think I'd trust a wheel which has been kerbed badly, and them knocked/bent/welded/patch back into shape.
Re: Dangerous alloys - important note. - John S
Ian, excellent point. Absolutely not to be trusted. If you need work done, which doesn't involve damage eg refinishing, ensure it's done on your wheels, and don't take exchange units!

Regards

John
Re: Dangerous alloys. - Flat in Fifth
I'm sitting with you here David, Its not strictly relevant but there is a big issue with spigot fit and non spigot wheels on HGV's. Of course the stud loading is in a whole different ball game here in a car as opposed to a 44 tonner, but I think its not right just to dismiss the effect of the spigot.
Re: Dangerous alloys. - Flat in Fifth
Oh yes I forgot to ask/say.

I bet a dye pen exam shows more cracks than you can shake a stick at, even on the one that appears uncracked to a visual exam.
Re: Dangerous alloys. - David W
Yep I'm familiar with crack testing from my previous life.

I am going to tell the chap even if he could find some new matching wheels not to keep that old one...and I wouldn't have the same make again.

I'm going to stick my neck out on the hub loading issue and say I'm sure I remember one of the other aftermarket wheels that has been on a vehicle here had slots for the wheel studs/bolts/nuts and all the location was on the hub. I guess this was to cater for several PCDs. Looked odd at the time.

David
Re: Dangerous alloys. - Richard Hall
David

I think the problem with alloys on Land Rovers is more to do with the halfshaft drive flange. All the wheels have the same stud pattern and spacing, but on some axles the drive flanges stick out more than others. The result is that the centre of the wheel hits the end of the halfshaft or the outer face of the drive flange just before the inner face of the wheel contacts the hub. You do the wheel nuts up nice and tight, but there is almost no friction between wheel and hub, so you get shear loads on the studs, and the wheels wobble around as they are not bolted squarely to the hub. Early Range Rover steel wheels on Land Rover axles are the most common example of this problem - they appear to fit OK, but they aren't safe without modification.
Re: Dangerous alloys. - David W
Thanks Richard, that fits in with my hazy memory of the issue for LRs.

David
Re: PS - Dave
DW wrote: "Yep I'm familiar with crack testing from my previous life."


Gynaecologist?
Re: PS - The
Don't know how relevant this is, but if you dent an aluminium ladder you're supposed to scrap it!