Hi Twofoot,
The main thing I did was to rebuild the curves to start with, so I could fillet after i extruded.. As with the original file I posted, i just deleted the verticle faces up to the fillt, then mirrored it under to create the spoke, to trim and boolean into the rim revolve...
So in the original file, you can see it is just a double extrude with fillets on the edges, then i deleted these verticle edges here and mirrored and joined it.
Rememeber I didnt use any dimensions from your files. I was just experimenting the method, so you cant use my files (I'm sure you see this)
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