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Old 12-28-12 | 02:50 PM
  #14  
Doug5150
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Joined: May 2005
Posts: 1,859
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From: IL-USA
Originally Posted by aljohn
As Fatty Chrimbo never dropped off a new Pinarello on his way past my house (perhaps the sled's brakes didn't work) I'll have to continue rebuilding my old bike. As I mentioned earlier I intend to fit new 700c rims to replace the sprint rims. I've bought the rims and the existing spokes are a tad or two too long. I know I'll probably be browbeaten into buying new spokes, but being tight I wondered if it is worth cutting them down and re-threading them? Is it easy to do (72 stainless) or am I dreaming? And a Happy New Year to all my readers.
The Hozan is the cheapest spoke-threading device there is, and it costs $200+. And over the last year people have complained about Hozan not having replacement rollers in stock, which do wear out.
The Phil Wood has a great reputation, but costs $2500-$3000+.
How many spokes did you need to make again?...

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Bicycle spokes use rolled threads, not threads that are cut using a die.

The technical necessity of the spoke threads being rolled is debatable, but one thing that is certain is that a normal hand-operated die will not cut threads longer than about 2 or 3 diameters at best before it begins to wander off-center and jams. No matter how square you start it, it isn't going to go straight for long. Bicycle spokes I've seen appeared to be threaded 4+ diameters.

You can also cut threads using a single-point tool in a lathe, but here again will not work for bicycle spokes, since they aren't really stiff enough for that.

A thread rolling machine squeezes the rod between three rollers, and this means that the rod being threaded always stays perfectly centered and the "wandering-off-center" issue you have with a cutting die is totally absent. Any length of threads can be formed this way: the 6-foot pieces of allthread rod that the hardware stores sell is rolled, not cut with a die. You can also form really tiny sizes easily this way, since the rod doesn't need to be particularly stiff.



If you are just wanting to clean up spoke threads, the thread size is #2-56 TPI. You can buy these dies online for $7, and a wrench to hold the die for a few bucks more. And yes it should cut threads, but probably not well.
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If you had machine tools at your disposal, it *might* be possible to build a little machine that held the spoke PERFECTLY straight & centered while the die turned PERFECTLY around the spoke--but this ain't gonna work doing it by hand.
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