Summary

A remix of http://www.thingiverse.com/thing:966836

Another remix, with a screw-on cap. http://www.thingiverse.com/thing:1036486

Instructions

A remix of my other cut-off wheel protector. http://www.thingiverse.com/thing:966836
Here's another remix, with a screw-on cap. http://www.thingiverse.com/thing:1036486

On this one, a cover protects the wheel's exposed face. My main concern was the lid wouldn't fit correctly, so I printed two sets. The lid is a perfect snap-fit on both.

The center hole is slightly tapered, smaller on the bottom end, so (theoretically) just 3 points touch the mandrel, minimizing friction.

If the fit is uncomfortably snug, I'd recommend forcing the mandrel all the way through the hole, thus enlarging it a bit.

If too loose, scale both the lid and body down by the same amount. Perhaps 1% (or less) will be satisfactory.

Seems safest to get it started, and pull the shank end through until the wheel seats, rather than push on the wheel end.

On an Afinia, I used 0.30mm layers and slow speed (fine quality) plus fan cooling. A set took 27 minutes, and used 10g ABS.

Metric and SAE files provided.

Dremel wheel cover remix