Patent ID: 7767046

Claim:
A process for permanently attaching an overlay having an outboard surface and an inboard surface to a wheel having an outer surface and at least one predefined opening therein, said process comprising the steps of: locating said overlay in a fixture; positioning said wheel on said inboard surface of said overlay defining a cavity between said outer surface of said wheel and said inboard surface of said overlay, said overlay having at least one predefined opening therein, said at least one predefined opening of said wheel peripherally surrounding said at least one predefined opening of said overlay; clamping said overlay and wheel to a pallet; heating said overlay and said wheel to a predetermined temperature; engaging at least one localized nest in said at least one predefined opening of said overlay and said at least one predefined opening of said wheel so as to create a localized area of said cavity between said inboard surface of said overlay and said outer surface of said wheel, whereby a mold is made of said cavity; injecting a foamable liquid in to said cavity; curing said foamable liquid; disengaging said localized nest; and, unclamping said wheel and said overlay from said pallet.