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I recently bought a plasma cutter and needed the wheels similar to what you would use with a oxy/acet kit.  So I decided to make 1 instead of buying 1.

I started off with a peice of ally shaft 60mm OD and 30mm long.  I machined 15mm down to 30mm and machined a hole to a size of 22mm.

I then made sure my cutter plastic shroud fitted properly.  A good fit.

I moved the peice to the mill and set it up in the vice so I could machine a groove about 1inch wide using a 1 inch end mill.  This is what I finished up with.

Happy with what I had done so far, I moved the peice into the rotary table and machined off all 4 sides so they were square.

Then trouble struck!!!  I machined a bit too big a cut and 1 side was ripped off with the end mill.

Now I have to start agian from scratch.  Stay tuned!!!

Mtw fdu.

Back again guys and I have finished my guide wheels.  Here is a pic machining the wheels.

Here is a pic of everything made and all layed out on my bench ready for assembly.

Here is a pic of the whole thing along side the oxy/acet wheels.

And this final pic of it on my plasma cutter.

Mtw fdu.

Jerry, Thanks for the reply. 

If you look a couple pics up with the exploded parts ready for assembly, those little "axles" are put through the hole and are solid riveted in with a hammer.  They don't actually move at all.  I have left a little room(maybe .5mm) on the width of the wheel so it moves freely without actually turning.  It works really well.  They do not "wonder" at all.

Mtw fdu.