Finished the first wheel (protype2) today. all up weight with tyre and heavy duty tube is 4.5kg 3/4kg lighter that last years wheel and I think it will be a lot stronger.
Process1. Lay up discs 5 layers of 8oz woven fibreglass. (epoxy resin used for all parts)
2. Glue 26" mountain bike rim with one side cut of to disc (pic1 and 2)
3.Make up joining strip and 4 spokes from 4 layers of 8oz woven (pic 3)
4. Fit spokes and joining strip to one side of disc. (pic4)Spoke holes work as key in
5. Trim joining strip and spokes and join both halves. Check that everything is square before epoxy sets ((pic5)
6. epoxy 1 layer of 2" fibreglass tape to tube well. (pic 6)
7. finished wheel.