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I'm trying to reproduce tank wheels ("ITALIERI" (LEAST PERSPECTIVE)):

enter image description here

But there are too many vertexes and merging can lead to ngons.

Edit:

Second file:

Edit #2:

Made some progress with the topology; overlapping faces/edges as described here:

but there are still highlighted faces that seem separated from the mesh (on the tip of the spokes).

Can't dissolve certain edges

Edit #3:

If there are two or more overlapping faces with the same normals the resulting face appears "brighter".

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Your topology is a bit messy, to quickly fix it you can:

  • Only keep one portion:

enter image description here

  • Fix the topology, give it a Mirror modifier:

enter image description here

  • Create an empty at the current origin of the object:

enter image description here

  • Give your object an Array modifier, deactivate Relative Offset, activate Object Offset with the empty as Object, rotate the empty 37,72° (as you want 11 iterations), enable the Merge option then the First and Last option:

enter image description here

  • Keep a copy of your object and empty. Apply the Mirror and the Array modifiers, then Merge By Distance to remove any overlapping vertices:

enter image description here

Edit:

Your topology is still bad, your faces are overlapping, etc:

enter image description here

Once you'll be good, you can extrude, use the LoopTools to make sure that you have nice circles, bevel the angle so that it will sharp when you'll have the Subdivision Surface modifier, etc...:

enter image description here

enter image description here

enter image description here

enter image description here

Also you may need to keep only 1/11 of your object again and use the same Array modifier around an object, it allows you to work precisely on a portion of the object without having to repeat the operations all around.

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  • $\begingroup$ Thanks! I still have overlapping edges and am unable to select the center edge loop (circle) to be extended. I'll keep trying. $\endgroup$
    – Sebi
    Commented Oct 4, 2020 at 13:22
  • $\begingroup$ Ok. I get something roughly similar but only when not applying the subsurf modif. $\endgroup$
    – Sebi
    Commented Oct 4, 2020 at 13:57
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    $\begingroup$ what do you mean? Maybe share a second file $\endgroup$
    – moonboots
    Commented Oct 4, 2020 at 13:58
  • $\begingroup$ Ok. Edited (reuploaded). $\endgroup$
    – Sebi
    Commented Oct 4, 2020 at 14:13
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    $\begingroup$ look at picture #2, you need to make sure that the shape is 1/11 of the whole ring and that you have quads with no overlapping vertices/edges/faces. You need to continue working on this part until it works fine, then you can apply the modifiers $\endgroup$
    – moonboots
    Commented Oct 4, 2020 at 15:08

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