Originally Posted by
gyozadude
My experience with the spokes that come with three different Alex wheelsets out of China or Taiwan was that tension alone wasn't the issue. Heads aren't matched to hub flange. The curvature radius on all the spokes was too large. I didn't know or really care at first. I just lubed the nipples, loosened all the spokes front and rear, re-tensioned and rode on them. The rear wheel on the set I rode failed at 800 miles +/- 50 miles for 3 spokes. That's when I took it apart and replaced all the drive side spokes. But then the non-drive side failed, so I replaced another 18 (total 36). Been fine now for 2000 miles or so. But the radius on the old spokes was considerably longer than the wheelsmith ones I replaced them with. The front, I took apart, then rebuilt using small brass washers on the head where it presses up against the hub flange. Surprisingly, the front wheel, with original spokes and the washers has lasted close to 3k miles. It simply doesn't see the stress, especially when I sprint up hills, which is when I hear the snap/ping and look down to see the potato chip. Knock on wood, hopefully the new spokes hold. The other sets went on bikes for sub 150 lb riders. Not a single issue reported in year now. There are clearly challenges to big guys looking for good, CHEAP, wheels.
Sure is hard to build a decent bike for big guys on the cheap. Hopefully this project does not become too much of a money pit. Thanks for the info man!