Smoothing the Wheels

Since I don't own a lathe, the best way I found to smooth the wheels while keeping them round was to screw a short section of 1/4" all-thread into the hole left by the hole saw pilot bit and chuck the other end into the drill press. With the drill press running on low, I used a piece of 100 grit sandpaper to flatten the wheels.

With the all-thread still attached to the wheel I used it as a handle to run the wheel through the 1/4" radius round over bit on the router table. I removed the all thread and threaded it into the other side so I could round over the other side of the wheel.

Finally I chucked the wheel back onto the drill press and finish sanded the wheel. Of course I had to repeat this for all four wheels.