Corvette C5 Modulare Forged Wheel Install

Stop, Drop, And Roll, Part 2: A behind-the-scenes look at how Modulare Forged builds its show-quality three-piece wheels

Justin Cesler Dec 18, 2013 0 Comment(s)
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If you’ve ever wanted to upgrade the wheels and tires on your late-model Corvette, you’re well aware that a lack of options is not a problem. Indeed, the aftermarket is chock-full of choices, with manufacturers offering everything from low-buck replica rims to high-dollar custom units and everything in between. But regardless of your specific performance, aesthetic, and budgetary requirements, finding the right supplier is key to ensuring a successful upgrade.

For our latest wheel project, we teamed up with the pros at Modulare Forged, who were kind enough to walk us through the process of constructing a set of their three-piece wheels. Modulare Forged has been building high-end multi-piece and monoblock (one-piece) rims for nearly 10 years, and in that time the company has established a enviable reputation based on its use of quality materials, interesting designs, and customizable finishes.

Best of all, Modulare designs, builds, finishes, and ships from right here in the United States, and each of its wheels is backed by a two-year limited warranty. More than 30 different designs are available, in diameters ranging from 18 to 24 inches and in a variety of widths to fit almost any chassis. All of the centers are machined and finished to the customer’s specifications, so they’ll fit on almost any Corvette ever built. Just pick a style, send in your specs, and you’ll be up and rolling again in no time.

We had a couple of specific requests on our C5 Z06, and Modulare was happy to accommodate. First off, we needed a wheel that would clear the C6 Z06 brake kit we installed in our last issue. The big, six-piston brakes mandated rims with increased spoke clearance and a larger diameter—a common requirement when upgrading Corvettes in this manner.

Second, we needed a staggered (19-/20-inch) set of wheels compatible with tires that would maintain the C5-specific 0.5-inch tire-height stagger. This would keep the ABS, Competitive Driving, and traction-control systems happy without throwing any trouble codes or putting the Z into “limp home” mode.

We were also looking for a classic design that was both aggressive and modern, to give our Z a timeless look without overpowering the other design elements we’ve come to know and love on the almost-10-year-old body. And finally, we wanted a true three-piece wheel that was built with race-inspired technology for the street, without any compromises.

Follow along now to see how Modulare does it, and then check out the company’s website to find a set that fits your requirements.

Forged Aluminum Blank 2/31

01 The construction of a Modulare Forged three-piece wheel starts here, with a quality T6-6061 forged aluminum blank center. Each blank is inspected by Modulare technicians for flaws or imperfections prior to heading to the lathe. There, the correct profile is cut into the aluminum, after which the center is handed off to the machine center.

Haas Mill 3/31

02 Transforming a forged aluminum blank into an actual wheel center takes hours of precision machining, and every Modulare wheel goes through the same process, regardless of the final design. With the blank inserted into the company’s state-of-the-art Haas mill, a technician loads the correct wheel-profile program, and the machining process begins.

Intial Hub 4/31

03 Starting in the center, the Haas machine cuts the initial hub bore into the wheel; this will serve as the center for all future cuts and modifications. In a C5 application, the bore is roughly 70.6 mm. Modulare machines a stepped lip into each hub bore, to allow for an O-ringed center cap to be installed later on in the assembly process.

Bore 5/31

04 Every step of the way, Modulare technicians check and double check the work of the machines. Here, the depth and alignment of the hub bore are verified before any further work is done to the wheel center. A mistake here would be multiplied over each additional step, resulting in an inferior wheel.

Drilling Lug 6/31

05 Once the techs are happy with the measurements and alignment of the center bore, the Haas mill is ready to take on the next step: drilling the lug pattern into the wheel center. Both C5 and C6 Corvettes feature a 5x120.65mm (5x4.75-inch) pattern, which is machined for a perfect fitment.

M6 Model Wheel 7/31

06 After verifying the bolt pattern is correct, it’s time to begin cutting a pattern into the wheel centers. Modulare has dozens of beautiful designs available, and only you can decide which look is right for you. For this particular build, we chose the company’s M6 model, which is a multi-split-spoke wheel with a modern look.

Initial Cuts 8/31

07 A lot of aluminum has to come out of the center to achieve the M6 design, and each step requires a different tool to get the job done. The initial cuts are made with a faster bit, and the Haas machine dials up more-precise tooling as it gets closer to the final design.

Drill Outer 9/31

08 With the spoke work almost complete, it’s time to drill the outer lip of the wheel center for the bolts that will hold the rim together. As with every other step, precision here is critical, as the bolt holes must align perfectly with both the inner and outer barrels of the final wheel assembly.

Wheel Outer Lip 10/31

09 We’re not sure what the dollar sign above the top bolt hole means, but we’re guessing it means that these centers look like a million bucks. Notice how the outer lip has been milled with a pocket between the spokes; this reduces weight while also improving looks. At this point, the front of the wheel center is done, but the back still needs to be machined.

Wheel Flip 11/31

10 This is done by flipping the wheel over and running the remainder of the program. The bore is cut to our 70.6mm specification, and the center of the hub is cut to remove weight. It’s this attention to detail and performance that makes a wheel like this stand out from the crowd.

Wheel Technician 12/31

11 Once the center is done being machined, it is meticulously inspected by a technician, who hand deburrs each one before giving it the OK and sending it to the finishing department. And that’s just one wheel—we need three more centers just to get the Corvette rolling!

Wheel Buffed 13/31

12 Regardless of the final finish, every wheel center heads to the finishing department, where it is buffed, polished, brushed, or sanded to perfection. Our M6 wheels were ordered with brushed aluminum centers, and Modulare takes the time to brush each one by hand for a perfectly uniform appearance.




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