Hi GrandeP,

> Michael, from what I've seen it looks like you build up the basic shape of the wheel and
> then boolean the crap out of it, is that right? Add fillets, blends etc etc afterwards?

Yup, that's basically it. You can use Revolve to build the base shape.

Check out here for some other techniques using Flow:
http://moi3d.com/forum/index.php?webtag=MOI&msg=5470.1

- Michael