SCORE Journal - The Official Publication of SCORE Off-Road Racing
Issue link: http://read.uberflip.com/i/1535528
WHEEL SCIENCE Inside the Engineering Behind Baja-Proven Race Wheels By Micah Anderson If tires are the boots of a race vehicle, then the wheels are the laces, critical components that keep everything secure when the terrain turns brutal. In today’s high-stakes off-road racing, wheel technology is being pushed to its limits. SCORE Trophy Trucks are bigger, faster, and more powerful than ever, putting down massive horsepower through advanced all-wheel drive systems. To keep up, standard tire sizes have ballooned to 40-inches that dominate the full-size ranks, while UTVs also now roll confidently on larger 37-inch tires. The evolution of modern off-road racing braking systems has only accelerated this trend. The use of larger rotors and calipers requires the need for larger wheels. The result? A tightly packed, hyper-competitive field where races are decided by seconds, drivers are braver than ever, and speeds regularly blast past the triple-digit mark. In this ever-escalating performance war, wheels are more than just rolling hardware, they’re foundational to the success of any race program. Materials, construction methods, strength, weight, offset, beadlock tech, and even styling all play a role in keeping a race vehicle alive in Baja. To uncover where wheel tech is heading, SCORE Journal spoke with several leading manufacturers and off-road racing insiders, including John Remus of Method Race Wheels (the official wheel of SCORE International), Rhett Sanders of Raceline Wheels, Chris Vorhies of Vision Wheel, Jaime Zamora of Tremrr Wheels, Will Cross of ROH Wheels, and Ryan Interrante of Torque Wheels. Here’s what they had to say about what it takes to keep racers rolling at the edge of controlled chaos, and simple physics, for that matter. What specific engineering or design features set your off-road race wheels apart when it comes to surviving Baja-style terrain and abuse? Method Race Wheels’ mantra states “Lighter. Stronger. Faster.” and ultimately, that is their goal with each wheel product. “It’s all about maximizing strength without unnecessary weight,” the Ecommerce Director at Custom Wheel House explained. Wheels like the 202 forged race wheel achieve an astounding 4,000 lb. load rating with high-strength forged 6061-T6 aluminum material combined with T6 heat treatment construction can produce higher load capacities and with lower overall weight. It is all optimized through finite element analysis (FEA) to manage real-world load paths. Additionally, key features like their patented Bead Grip technology, reinforced barrel lips, and inner oversized beadlock ring hardware are designed with desert-specific stressors in mind. Raceline Wheels leverages over 20 years of race-winning experience to continually improve its wheel products. Their competition beadlocks utilize forged billets and deep lug pocketing for strength under severe torsional and vertical load and are constantly working to refine load-bearing structures and lip reinforcement strategies. “We use Grade 8 yellow zinc beadlock bolts with hardened steel captive washers and PEM nuts embedded in the wheel,” declared Raceline’s Rhett Sanders. “These allow the beadlock ring bolts to be replaced without ruining the threads in the wheel itself, which is a major problem in the field. We also cast and machine in-house to ensure full QC oversight. Raceline is the only brand currently doing this in the USA.” Vision Wheel incorporates OEM-level CAD collaboration with brake and suspension engineers to ensure strength, clearance, and fitment. Their race wheels are built from race-validated aluminum alloys and undergo real-world development alongside their teams. Standout innovations include Vision’s Tire-Lock Technology, which is essentially an aggressive bead lip channel integrated into the inside and outside of the wheel barrel, securely trapping the tire to the wheel. Additionally, an upcoming carbon fiber UTV race wheel is just over Vision’s horizon and is designed to minimize unsprung weight without compromising strength. Tremrr Wheels brings a tire-first approach to wheel design that’s grounded in real-world racing experience Jaime Zamora noted. “Keeping up with what all the tire manufacturers do on bead pack and sidewall thickness makes a big difference,” says Zamora. This attention to detail fuels Tremrr’s development of both forged and cast wheels with reinforced “Tire Seat Channels” that protect inner and outer beads from breakdown. Their patented Tremrr Tire Lock System—a 45-degree stepped mounting profile that locks both beads firmly in place—has been tested to perform at pressures as low as 12 PSI on 35-inch tires, offering exceptional performance in Baja-style conditions. ROH Wheels brings Australian Outback credibility to SCORE-style racing. Their heavy-duty forged wheels are built to resist radial impact, flange deformation, and bead seat failure. Designs are influenced by sustained high-speed abuse and long-term lateral loading. Will Cross, Marketing Coordinator for ROH Wheels stated their products are built to hold up to rugged abuse with the forged 6061-T6 aluminum beadlock rings and heat-treated cast alloys in the wheel body. Lock Off-Road designs feature proprietary forging profiles and aircraft-grade aluminum to optimize impact dispersion and reduce stress concentrations. Deep lips and high strength beadlock assemblies anchor the wheel to the tire under extreme duress. “We run forged 6061-T6 aluminum wheels and forged rings to improve both strength and ductility,” said American Wheel Group Marketing Manager Ian Horne. “The beadlock hardware uses grade 10.9 zinc-coated bolts, and our wheels feature thickened lips and reinforcement in high-stress areas. The spoke geometry is functional, not cosmetic.” Torque Wheels takes a form-follows-function approach, building with thickened flanges, tall bead humps, and material only where needed. Their designs come directly from abuse testing in Baja, including thousands of miles on spec vehicles like Baja Challenge cars. “We increased flange thickness and bead hump height to improve strength and tire retention,” revealed Ryan Interrante, Chief Operations Officer for OE Wheel Works and Torque Wheels. “Our forged 6061-T6 aluminum construction means we can add structure where needed without adding weight. These wheels are designed to survive and win in Baja.” How do your teams test or validate wheel strength and durability before a wheel is deemed race-ready? Method exceeds SAE J2530 benchmarks with a combination of destructive lab testing and field validation. Cornering fatigue, radial fatigue, and impact resistance are all verified, but real desert mileage is the final stamp of approval. Raceline applies SAE testing protocols and its own field torture test programs with sponsored drivers. Feedback from teams in Baja and other race series informs iterative improvements. Their forged beadlock wheels must endure sustained heat cycling, pressure differential, and high-G hits. “We use FEA modeling to optimize design pre-production,” Sander declared. “We validate in the field — short-course, desert, rock crawling, you name it. The Pro Series beadlocks are on vehicles competing in the most brutal events in off-road racing.” Vision Wheel uses modified SAE J2530 tests at the factory, combined with proprietary durability trials. According to Chris Vorhies of Vision Wheel, “We also use data collected from our teams to constantly improve the product.” Tremrr Wheels uses a mix of FEA-based design validation and real-world performance testing to vet every wheel before it’s approved for racing. “We go beyond basic ratings,” says Zamora. “We test how the wheel performs when it’s deflated, flexing, or under the weight of a moving vehicle without a tire.” The forged 17x9 Trophy Truck wheel, for instance, carries a 3,700 lb. load rating and is designed to perform even under the grueling conditions of desert racing. Their 15x7 104 Aftershock UTV wheel is equally robust, rated at 1,600 lbs. and tested for sidewall pressure retention, impact strength, and endurance in high-speed off-road scenarios. ROH runs wheels through multi-axial fatigue cycles at over 1,500kg loads for up to one million repetitions. Additionally, corrosion and impact resistance are validated under field-simulated conditions. Cross expounded, “All wheels are lab tested in-house to both Australian and international standards — impact testing, fatigue testing (radial and cornering), and load ratings at or above 3,300 lbs. per corner. We also conduct real-world testing in Australia’s outback, which offers desert, washboard, rock, and red dust, essentially Baja, just upside down.” Lock Off-Road begins with FEA simulations with Baja-style stress loads to identify stress points before production, then transitions to physical radial and impact testing. Field testing in real race scenarios validates their simulations. “All our wheels are run on team trucks for thousands of miles, on every surface we can throw at them.” Torque relies on Baja itself as the ultimate lab. “We launched our brand by taking our wheels to Baja and deliberately trying to break them,” said COO Ryan Interrante. “We design and engineer in the USA, and the owner, Joe Interrante, has multiple SCORE Baja 1000 podiums, so we know what ‘race-ready’ truly means. The TW301AF Canyon has logged thousands of miles in the Baja Challenge series as the spec wheel.” How has the evolution of tire sizes and suspension travel changed the way you design wheels for today’s off-road vehicles? Method has adjusted spoke structures, hub interfaces, and ring hardware to handle the increasing demands of tire size, higher speeds, and massive impacts. Bigger tires mean more rotational and side-load force. “For race vehicles, we try to understand what’s ahead by working with OEs to know the market and plan accordingly. With the consumer market, it’s a constant requirement to have a finger on the pulse for what’s hot and what’s in demand and understand current trends and fitments to the market desires.” Raceline responded by reinforcing load zones and adjusting spoke design for higher impact deflection. Taller sidewalls and increased leverage from modern tires necessitate stiffer barrel and ring geometries. “AWD trucks and larger tires are the trend, and that changes offset requirements and how forces are transferred to the wheel. That’s why we offer forged Ryno Beadlocks in 4.5” and 6” backspacing. The days of ‘standard’ fitments are over — we’re now engineering for specific racing applications.” Vision Wheel integrates modern suspension geometry and brake layout into its wheel designs. They collaborate with suspension and chassis builders to tailor wheels around known mechanical stress and clearance issues. Tremrr Wheels design wheels that clear bigger brake profiles but also maintain correct tire profiles for sidewall performance. Zamora explains “With modern race trucks running larger brake packages and more aggressive suspension travel, Tremrr has focused on fitment solutions that accommodate those components while preserving strength and safety. Whether it’s 5, 6, or 8 lug patterns in the truck lineup or multiple lug options for UTVs, every Tremrr wheel is purpose-built to handle the demands of today’s high-performance off-road platforms.” ROH has focused on reducing rotational mass while increasing rigidity. Their LiteForged wheels are tuned to avoid deflection while shedding weight—a key advantage with longer travel suspension systems. “The shift toward bigger tires and longer suspension travel means wheels are under more stress than ever. There’s a real demand now for strength without unnecessary weight.” Lock Off-Road designs for resistance to barrel flex and lateral load dispersion. Larger tires exert greater torsional stress at the bead interface, so Lock reinforced both the bead seat and hub contact areas. “The increase in unsprung weight and wheel speed creates unique stress vectors. We now add material where it’s needed most and validate that with FEA. Suspension travel and longer arms mean more leverage — our wheels are designed to hold up under torsional loads as much as impact.” Horne explained, “We’ve increased lip thickness, refined our ring hardware torque retention, and reinforced load-bearing zones in the barrel to account for the torque loads from larger tires and more aggressive off-road driving. It’s no longer just about clearing a brake caliper — it’s about engineering a wheel that can survive repeated hits while keeping the tire locked and the rig planted in the harshest conditions.” Torque Wheels built thicker flanges and taller safety humps into their newer designs. Their FEA models help predict where forces accumulate and where materials can be removed without compromising performance. “Larger tires create more strain from rotational mass and leverage. Using FEA, we find the exact zones of weakness and reinforce them without making the wheel heavier across the board. It’s precision engineering — not guesswork.” What trends are you seeing in wheel design or material innovation that racers and builders should be paying attention to in the next year or two? Method is developing hybrid-forged models that offer high strength-to-weight ratios and reduced cost. Their use of advanced machining allows for modular updates to existing platforms. Remus continued, “Trends are ever changing. The truck and off-road market are no exception. With larger vehicles, the demands for heavy-duty applications, larger offsets, newer finishes, as well as ways to customize and make your wheels fit your personal style are all key things we strive for. Raceline sees demand growing for customization and team-specific solutions. Precision machining and modular designs allow faster adaptations to changing vehicle platforms. “It is not about trends, but more important to stay on brand and true to our racing roots. We work hard to make race wheels in both cast and forged aluminum that offer a superior strength-to-weight ratio.” Vision Wheel is investing in advanced materials. Their upcoming carbon fiber wheel for UTVs reflects a shift toward exotic material use in off-road racing. Tremrr Wheels categorizes wheel construction technologies by application and aggressiveness: “Cast aluminum 356 is used by most racers who aren’t as aggressive. Flow formed is newer and some savvy manufacturers are integrating the construction process into their lineup. It is not used by many yet. Forged 6061 aluminum is the top of the line, and that is what the premier teams use for greater quality, durability, and custom size availability.” Tremrr embraces these distinctions while carving out its niche with high-load ratings, like 4,200 pounds on 8-lug truck wheels, and next-gen features such as dual valve holes (one for OE TPMS, another for fast deflate/inflate systems) across their truck and UTV lines. ROH expects increased application of fatigue-resistant alloys and forging profiles designed around telemetry data, particularly in long-distance rally and desert formats. “It’s no longer just about making something strong and durable,” Will shared. “It is about optimizing every part of the wheel to work harder with less weight and more efficiency. Lock Off-Road is exploring integrated ring venting, improved coatings for corrosion resistance, and bead seat geometry innovations for better retention under low-PSI scenarios. “Builders and racers are realizing that shaving unsprung weight makes a massive difference in suspension responsiveness and overall vehicle control, especially in high-speed terrain like Baja,” Horne acknowledged. “We’re also seeing a rise in modularity — things like interchangeable beadlock rings, reinforced hardware systems, and dual-drill fitments that allow for cross-platform compatibility without sacrificing strength. On the styling side, aggressive concavity, functional venting for brake cooling, and multi-layer finishes are becoming more common as vehicles get more complex and visually refined.” “And beyond design, racers should watch for smart manufacturing — CNC precision machining with tighter tolerances, aerospace-grade coatings for corrosion resistance, and data-backed testing protocols. The next era of off-road wheels isn’t just about looking tough — it’s about being engineered to handle real abuse with the science to prove it.” Torque Wheels notes increased synergy between aesthetics and function. Their customers want high-performance, race-tested wheels that still look aggressive. “On forged wheels in particular, advancements in CNC tool tips and computerized manufacturing processes are allowing us to create styles that are still as strong or stronger than previous styles, but we can improve on the design, so the wheels look as good as they are strong. You no longer sacrifice style to race on a durable wheel.” How do your wheels address both strength and serviceability in a race environment where quick pit stops, or field repairs are critical? Method uses deep chamfers, oversized lug pockets, and corrosion-resistant hardware. Their beadlock designs are optimized for fast torque cycles and pit-friendly maintenance. “Race is our middle name, and Stronger is the second part of our motto. And in some events, seeing a racer with a blown tire, threads hanging on, and that vehicle cross the finish line with the wheel intact is a spot of pride that our products are doing exactly as they’re designed to do. Features like the 4,000 lbs. load rating, the forged beadlock rings, redundant mounting holes, or trusting that Method has tested these wheels harder than they’re going to push them, provide customers with a ton of confidence knowing they are rolling on the best out there.” Raceline builds wheels with quick-access lug areas and ring bolt indexing for efficient service. Their hardware is tested for repeated heat cycling and on-the-fly changes. “We listen to our teams and what they need, and we build our race wheels to their specifications that they require. For most of our teams, we custom drill their wheels to what they ask for, to work best on their trucks during the entire duration of their races...these are all custom drilled in our facility here in Southern California.” Vision Wheel prioritizes fast clearance and serviceability by working with crews directly. “We design for real-world glove fitment and tool access,” Haney said. Their beadlock rings and fasteners are rated for multiple reinstallations. Tremrr Wheels are engineered for chaos to survive deep in the desert with a tire failure. “Engineering is key when designing a race wheel,” says Zamora. “It needs to be as light as possible yet be able to be driven on without a tire during a race to get to a pit stop or location to change out.” That balance of strength and serviceability defines the Tremrr difference. “We also want the wheels to look great no matter what,” added Jaime. “With our sleek, race-inspired styling, these wheels don’t just perform, they turn heads doing it.” ROH factors in pit speed with features like wide-open lug pockets, low-friction coating on threads, and rapid-alignment hub bores. Lock Off-Road machines generous clearance around the lug areas and include heavy-duty, reusable hardware. Their service-centric design comes from working with pit crews during testing. “We designed our wheels with impact guns in mind for real-world serviceability. The lug holes are positioned and chamfered for easy access, even under pressure, allowing for quick changes without interference.” Torque Wheels uses oversized lug bores and accessible ring bolt patterns to ensure quick changes. According to Interrante, “The large, open counterbores allow for easy impact wrench access for quick changes in the field and during pitting.” Conclusion: The Anatomy of a Championship Wheel Every component on a SCORE race vehicle is critical, but the wheel stands alone as the literal ground interface. Method, Raceline, Vision, ROH, Lock, and Torque all bring different engineering philosophies to the table, but each shares a relentless drive for durability, field serviceability, and real-world validation. Whether forged aluminum or future-forward carbon fiber, these race wheels are designed not just to finish, but to finish first. SJ