Sanding the pieces:
After everything is cut out, drilled, and otherwise fabricated, it's time to do some sanding of the pieces so you make a wooden wagon wheel that is finished well, and will look more attractive in your yard.
You might choose to make it look like an antique; or perhaps you would prefer something more colorful; or maybe jet-black; or white-white; or whatever suits your personal tastes! In any case, to make a wooden wagon wheel that best suits your specific needs, wants and wishes, use your personal choices and touches to make it something you are truly proud of!
My recommendations for dimensions and materials, to make a wooden wagon wheel that is attractive and decorative, yet lightweight enough to handle safely and easily are as follows:
-Wheel diameter: At least 36"; up to 48". Make from 5/4 x 6 deck board material, in eight equal arc-segments.
--Wheel rim-segments: At least 1" thick; width to be whatever can be cut from standard 5/4 x 6 pressure-treated deck boards. Length is determined by dividing the chosen wheel size circumference into the eight equal segments.
-Wheel spokes: Length is determined by the wheel diameter and the hub size; plus the depth of the drilled holes in those items. The diameter of the spokes is determined by the chosen thickness of the rim-segments and wheel hub. For fitting into standard 5/4 pressure treated deck board material, spokes should be no larger than 3/4" diameter, which will leave only about 1/8" material on either side of the holes (sufficient for this decorative-only wooden wagon wheel). If your local home center or hardware store carries pressure treated dowels, use that; otherwise, standard dowel material is alright as long as it is protected by a good exterior finishing product.
-Glue: Use a superior-quality, exterior grade wood-bonding adhesive. There are many to choose from; read the labels carefully, or ask for assistance at your home center or hardware store for best results.
-Finishing products: Use high quality, exterior-grade stains, varnishes, paints or other sealants and protectants designed for exposure to elements germane to your area.
-Wood filler: You will need a small amount of wood filler, to fill the screw holes around the outer rim after final assembly.