FIrst, I know nothing about changing tires on a bicycle, but the captain does. He has done this (both for regular maintanance and on the road after flats) for 20 plus years. When we got our tandem it had Vittoria Rubino Pro 700x28 tires and we had 6 flats in 8 weeks. Changed lots of them. Then we switched to a sturdier Panaracer RIBO 700x28 tire, and still using the Performance 28-32 tubes and it seems that 30-45% of the time when he changes a tire and pumps it up again the tube blows. He has used the same technique he's used for years but said the bead on the tire must be hard to set. This last time he put 2 new tubes and two existing tires with 1000 miles on and prepared them carefully, going around the rim and hand checking everything and then cautiously pumped them up to only 80 psi and let them sit overnight that way. The next day he finished pumping up to 120psi and one of the two--BOOM-- and a 2-inch split in the tube. This is NOT happening at the valve stem. I, of course, am the nervous stoker who is afraid that someday we will be stuck in the rain along side a road with no shoulder (and uphill both ways and we'll have a flat and when we change it the tube will BOOM again and we'll be stranded if we blow up the 2nd spare tube also. If it's so difficult to keep this from happening in the ideal conditions of our garage, with a floor pump, etc. why should changing a tire on the road be any better? Has this happened to any of you, and if so how did you prevent it or how could you even identify that something was amiss and the tube was going to blow? This has happened on the same tires and tubes on two completely different wheelsets, so it's not the wheels.