How incredible tight tolerances were achieved

It seemed very difficult to build a wheel so large within the original requested diameter tolerance of 150mm. In fact, the party who originally won the tender, gave the project back as they thought it to be too complicated.

Mercon had to find a smart solution to ensure tolerances would stay within the required limits.

We came up with the idea of a master jig. Sections of the rim’s triangular truss were completed, three at a time, on this master jig to ensure that each section aligned perfectly with its neighbor. In the end the overall diameter tolerance of the wheel was reduced to only 25mm; an impressive achievement.