From Billet to Precision: Manufacturing Angelo Magtoto's AR-i8 Race Wheels
- Brinal Chua
- Dec 22, 2025
- 5 min read
After weeks of design refinement and FEA validation, Angelo Magtoto's AR-i8 wheels moved from digital blueprints into production. The renderings we approved became CNC programming. The stress simulations became quality control benchmarks.
This is what happens when engineering meets execution.
Key Takeaways
6061-T6 aerospace aluminum forged under 10,000 tons of pressure creates directional grain structure
Multi-axis CNC machining transforms forged blanks into precise 18x11 ET35 specifications
Hyper silver finish applied through multi-stage process: polishing, coating, protective clear layer
Red engraving paint fill applied with precision to "Autoholic Racing Paddock Club" and "Angelo Magtoto"
Final wheels validated against FEA predictions before delivery to Philippines
Table of Contents
Forging: Creating the Foundation
Angelo's wheels began as solid 6061-T6 aluminum billets, carefully selected for material consistency and traceability. Unlike cast wheels that pour molten aluminum into molds, forging compresses solid metal under extreme pressure.
Our manufacturing partners use a 10,000-ton hydraulic press. That level of force doesn't just shape aluminum; it restructures it at the molecular level. The pressure aligns the metal's grain structure directionally, creating strength characteristics impossible to achieve through casting.
This grain flow is why forged wheels can be lighter than cast equivalents while handling higher loads. When we calculated Angelo's AR-i8 wheels would see over 3,000 kg equivalent forces during 2+ G cornering, the forged grain structure became non-negotiable.
After forging, the wheel blanks undergo T6 heat treatment: solution heat treatment followed by artificial aging. This process achieves optimal hardness (typically 95-100 HB for 6061-T6) while maintaining ductility for impact resistance. Too soft, and the wheels deform under load. Too hard, and they become brittle, prone to cracking from kerb strikes.
The T6 designation Angelo saw in the FEA results and will see engraved on his finished wheels represents this specific temper state, validated to aerospace standards.
CNC Machining: Precision Takes Shape
The first manufacturing image shows Angelo's wheel mid-machining, clamped in a CNC mill. The cutting tool you see is carving the spoke profile from the forged blank, following the exact geometry we validated through FEA simulation.
Multi-axis CNC machining allows complex spoke curves and barrel contours impossible with traditional manufacturing. Every dimension—18-inch diameter, 11-inch width, ET35 offset, 66.5mm center bore, 5x112 PCD—is programmed to tolerances measured in hundredths of millimeters.
The AR-i8's Y-spoke pattern requires careful tool pathing. The deep valleys between spokes, the thickness variations we engineered for stress distribution, the chambered lug holes—each feature demands specific cutting strategies. Rush the process, and you risk tool marks, dimensional errors, or worse, structural weaknesses.
The machining chips visible in the image represent material removal from low-stress zones identified in FEA testing. We're not guessing where aluminum can be safely removed; we're following validated engineering data.
After rough machining establishes the wheel's form, finishing passes refine surfaces to final specifications. The spoke edges you'll see polished on Angelo's finished wheels? Those started here, with precision cuts that create the foundation for the hyper silver finish.
Finishing: Hyper Silver and Red Details
The finished wheel images show the transformation from raw machined aluminum to hyper silver race wheels.
Polishing and Surface Preparation
Before any coating, the wheels undergo multi-stage polishing. The barrel's machined texture you see in image 4—those fine parallel lines—represents the raw aluminum surface after final CNC passes. This becomes the base for the hyper silver finish.
The polishing process removes machining marks, creates uniform surface texture, and prepares aluminum for coating adhesion. Spoke edges receive additional polishing to achieve the bright metallic highlights visible in the finished product.
Hyper Silver Application
Unlike powder coating (which builds thick layers), the hyper silver finish maintains the machined aluminum's dimensional precision. The metallic coating creates depth and reflectivity while the protective clear layer guards against brake dust, track debris, and cleaning chemicals.
Notice how light plays across the spoke faces in the finished images. The dimensional contrast between polished edges and silver surfaces showcases the engineering complexity we built into the AR-i8 design.
Red Engraving Paint Fill
The red details visible on the barrel outer edge and spoke faces required precision application. "AUTOHOLIC RACING," "PADDOCK CLUB," "ANGELO MAGTOTO," and "AR COMPETITION" were engraved during CNC machining, then filled with red paint that's cured for durability.
These aren't vinyl decals that peel off after a few track sessions. They're permanent identifiers that will withstand heat, brake dust, and cleaning throughout Angelo's racing season.
Quality Control: Validation Before Delivery
Image below shows the hub face with load rating embossed: "MAX LOAD 1050 KG." This isn't marketing—it's certified capacity per wheel.
With Angelo's GR Supra weighing 1,520 kg with driver, static load per wheel approaches 380 kg. The 1,050 kg rating provides 2.76x safety factor before accounting for dynamic loads. When cornering forces multiply that weight (2+ G = effectively 760+ kg per front wheel), we're still within validated safety margins.
The hub face also shows:
ET35 marking confirming offset specification
CB 66.5 center bore dimension
JWL/VIA certifications embossed on spoke backs
Every wheel undergoes dimensional verification, balance testing, and visual inspection before approval. The finished wheels you see passed all checkpoints, matching our FEA predictions and meeting Angelo's specifications exactly.
The Result: Race-Ready AR-i8 Wheels
The final images show what weeks of engineering and manufacturing produced: four 18x11 ET35 AR-i8 wheels in hyper silver finish with red personalized engravings, ready for Angelo's GR Supra A90.
The spoke depth and machining complexity visible in these shots validate the design work from Blog 2. The FEA stress maps we analyzed are now physical reality, with low-stress zones carved away for weight reduction and high-stress areas reinforced with material exactly where needed.
The hyper silver finish creates the dimensional contrast we predicted when we shifted from Satin Grey. Light catches the polished spoke edges, reveals the Y-spoke pattern depth, and emphasizes the aggressive barrel profile.
From our first consultation about Angelo's time attack requirements to these finished wheels, the process took approximately 10 weeks: 2 weeks for design and FEA validation, 8 weeks for manufacturing and finishing.
These wheels now ship to the Philippines, where Angelo will mount them to his Supra, head to the track, and validate through lap times what we validated through engineering: that the AR-i8 design delivers the performance he needs.
Shipping to the Philippines: Final Journey Begins
With quality control complete and final inspection passed, Angelo's AR-i8 wheels are now packaged for international shipping from Singapore to the Philippines.
Each wheel is individually protected with foam padding and secured in custom packaging designed to prevent movement during transit. The hyper silver finish and red engravings we spent weeks perfecting need to arrive in perfect condition.
International logistics typically take 1-2 weeks depending on customs clearance. Angelo will receive all four wheels, center caps, and documentation including load certifications and fitment specifications.
The next blog in this series will cover arrival, unboxing, installation on his GR Supra A90, and the moment we've been building toward: his first track session on Aura Forged wheels.
What Makes This Process Different
Most wheel manufacturers don't show you CNC machining mid-process. They don't explain why 10,000-ton forging pressure matters or how T6 heat treatment achieves optimal properties. They don't connect FEA stress maps to material removal during machining.
Aura Forged's process maintains transparency from consultation through delivery. Angelo saw renderings before production, reviewed FEA validation before manufacturing began, and now receives wheels built to the exact specifications we agreed upon.
No surprises. No compromises. Just engineering executed with precision.
Build Your Custom Wheels with the Same Process
Angelo's AR-i8 wheels represent Aura's complete methodology: consultation, engineering validation, precision manufacturing, and quality control. Whether you're building time attack machines or upgrading daily drivers, the process remains consistent.
References
ASM International, "Heat Treatment of Aluminum Alloys," ASM Handbook Volume 4, 2024
Society of Automotive Engineers (SAE), "Wheel Manufacturing Standards," SAE J2530, 2024
Japan Light Alloy Wheels Standards (JWL), Ministry of Land, Infrastructure, Transport and Tourism, Japan
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