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Old 11-08-08, 10:04 PM   #1
silver_ghost
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Half my spokes are too long.

I used the DT Spoke Calculator to determine spoke length for a front wheel build on a Deore disk hub. I used the archived values for the Deore hub from DT's website, which, I realize now, must be for the non-disk version. I spaced, at the time, on the fact that a front disk wheel is not going to be zero dish and will not used the same sized spokes for each side.

So now I have a built up and half tensioned wheel with most of the left (disk mount) side spokes poking through both walls of the rim.

Do I have to totally take apart the wheel and rebuild with spokes 2-4mm shorter for the disk side or is there any way to safely lop off the protruding ends and save myself a bunch of work? Oh well, if I have to re-do it I guess I just get some more practice.
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Old 11-08-08, 10:39 PM   #2
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Good, high-end bike-shops may have a special machine for cutting spokes, and threading them, to custom lengths. One is made be, I believe, Phil Wood. Call around.
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Old 11-08-08, 10:40 PM   #3
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So long as the threads on your spokes are not bottoming out, you could always just file or grind (with a Dremel, or some such) the ends. I have respaced/redished numerous wheels for fixed gear use and have done this. It is sort of tedious, but doable.

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Old 11-08-08, 11:59 PM   #4
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I doubt he'd have 2-4mm of threads available before he bottoms out the nipples though. Really needs to rethread them for 4mm more threads before cutting the ends.
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Old 11-09-08, 08:24 AM   #5
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If it were me, I would redo the calculations and attain the correct length spokes. + star over on the wheel/
Cutting and/or rethreading is time consuming and difficult.
Correct length spokes are relatively inexpensive, compared to time/effort dealing with incorrect length spokes.
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Old 11-09-08, 09:05 AM   #6
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Originally Posted by silver_ghost View Post
or is there any way to safely lop off the protruding ends and save myself a bunch of work?
Nope.

You have to completely restart with new spokes of the correct length. If it was maybe 1mm too long then you could probably just file it down, but 2-4 is a no go. You would have to file/chop a lot off and you will be missing nearly 40% of the threaded section. Unless you extend the threads.

Which is a complete waste of time, unless you already have the tool and you want a rainy day project.

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If it were me, I would redo the calculations and attain the correct length spokes. + star over on the wheel/
Cutting and/or rethreading is time consuming and difficult.
Correct length spokes are relatively inexpensive, compared to time/effort dealing with incorrect length spokes.
+1

Sudden outbreak of common sense in this forum.
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Old 11-09-08, 04:17 PM   #7
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Good, high-end bike-shops may have a special machine for cutting spokes, and threading them, to custom lengths. One is made be, I believe, Phil Wood. Call around.
Totally. I happen to work in one. I just made the mistake of thinking I could handle the calculations myself instead of giving them to the head mechanic to look over before I started lacing. Live and learn.

Like I said before, the root of my problem is that I went be DT's measurements that were for a different hub than I actually had. From now on I'll do my own hub measurments regardless.

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I doubt he'd have 2-4mm of threads available before he bottoms out the nipples though. Really needs to rethread them for 4mm more threads before cutting the ends.
Good point Danno. Didn't think of that. To be honest I'm more concerned about the embarasment of going back to work tomorrow with my tail between my legs than I am with the cost of proper spokes. Oh well, more practice I guess. Thanks for your help everyone.
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Old 11-09-08, 04:26 PM   #8
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... Didn't think of that. To be honest I'm more concerned about the embarasment of going back to work tomorrow with my tail between my legs than I am with the cost of proper spokes. Oh well, more practice I guess. Thanks for your help everyone.
Don't feel too bad - this is a very very very common problem.
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Old 11-09-08, 08:57 PM   #9
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. . . the embarasment of going back to work tomorrow with my tail between my legs than I am with the cost of proper spokes . . .
In any field the persons who calmly says, "I blew if because . . . . and next time . . . ." gains the respect of his or her peers.
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