Abstract: A method of manufacturing a cast vehicle wheel including a wheel trim cover attached thereto. A removable first tool insert is installed into a mold assembly. The tool insert includes a mounting feature that communicates with a cavity of the mold assembly to form a mating feature in the wheel. A wheel trim cover is provided and is attached to the wheel at the mating feature via a coupler formed in the wheel trim cover such that the relative position of the coupler and the mating feature positions the wheel trim cover relative to the wheel in a first predetermined position. After casting, the positional dimensions of the mating feature of the wheel relative to the coupler of the wheel trim cover is evaluated to determine the positional accuracy of the mounting feature of the first tool insert. If necessary, secondary inserts with improved mating features are provided and exchanged.

Abstract: A method of manufacturing a cast vehicle wheel including a wheel trim cover attached thereto. A removable first tool insert is installed into a mold assembly. The tool insert includes a mounting feature that communicates with a cavity of the mold assembly to form a mating feature in the wheel. A wheel trim cover is provided and is attached to the wheel at the mating feature via a coupler formed in the wheel trim cover such that the relative position of the coupler and the mating feature positions the wheel trim cover relative to the wheel in a first predetermined position. After casting, the positional dimensions of the mating feature of the wheel relative to the coupler of the wheel trim cover is evaluated to determine the positional accuracy of the mounting feature of the first tool insert. If necessary, secondary inserts with improved mating features are provided and exchanged.