They use the process Hanno mentioned, by spinning the rubber onto the wheel then machining the correct profile.

I spoke to a representative of one of these companies at the Dorset steam rally a couple of years ago as I had a customer interested in having his wheels done and they said not a problem and gave the impression that they had done carrier wheels before, after all they are no different to any steam traction engine rubbered wheels.

The key phrase to look for is "mold on rubber wheel"
For those researching possibilities, this should narrow the search as I was able to come up with several vendors in North America and some who specialize in military and construction applications, short runs and prototypes.

Macks Rubber
 

Some time ago, the carrier guys at Lithgow gave me contact details of a NSW company who did re-rubbering of carrier wheels by the wrap, vulcanise & machine method. I sent the 4 top idlers for my Loyd down & had prompt service - no hassles (even included cartage both ways from Brisbane). The total cost was AU$484. I don't have a quote for the carrier wheels but just contact Brian at
http://www.macksrubber.com.au/

Recommended !

Looks great Des , was that price each or for the four ? maybe they could do lp2 carrier small top track support idler wheels . Dale

Weasel return rollers aren't so different from Carrier return rollers in size, apart from a lighter construction. We were considering getting our idler and sprocket wheels refurbished so I visited Queensland Rollers and Liners (http://www.rollersandliners.com.au) in Rocklea, Brisbane and they could redo them with the decent super-tough PU used for forklift wheels via the cast and machine method.

In the end the cost per wheel was equivalent to importing NOS Weasel idlers from o/s so we went that way. For your situation it might be worth having a chat to them.

Steve.

Here is the mold without the insert for the track adjustment wheel

Attachment 69040 Attachment 69041 Attachment 69042

I have tried to upload picture of the completed wheel with a little more than 100 miles on them but they must be to may pixels they will not upload
Sorry but wheels look and work better and are a lot cheaper than going the forklift route :bang:

Moulding Bogie Tires
 

Guys,

I have 2 rims now cleaned up and ready to put in the mould. I'm going to try a 2 part PU casting of the bogie tire. We are going to do a 20" diameter bogie tire and a 19" diameter tensioning tire.

As soon as they pop out, I take some more pictures.

Cheers