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Old 04-17-15 | 04:22 PM
  #22  
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Drew Eckhardt
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Joined: Apr 2010
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From: Mountain View, CA USA and Golden, CO USA

Bikes: 97 Litespeed, 50-39-30x13-26 10 cogs, Campagnolo Ultrashift, retroreflective rims on SON28/PowerTap hubs

Originally Posted by davidad
I don't think you are going to get a simple answer. I have only built one wheel with Al. nipples and did not care for the end result. They began to break when I touched up the wheel after 5 to 10k miles.
You could drip thin oil into the bottom of the nipple and turn it back and forth to make sure it gets in. If you go through that much trouble you may as well replace the nipples with brass.
I've never had problems with aluminum nipples in wheels I've built with spokes reaching at least the slot bottoms and properly lubricated threads and rim sockets, although I ran into a wheel built by someone else ridden in California which obviously wasn't done right and needed vise grips.

I built my first pair living in Boulder, CO in 1997 or 1998 where I rode them on roads with left over snow and a little salt although I used a spare pair with 27mm cross tires mounted when the snow didn't melt. Stored them living in Seattle 2006-2008. Moved to Silicon Valley in 2008 where I used the commuting up to 26 miles round trip including rain until using a Powertap September 2010-March 2011 and getting serious about training with power in April, 2014.

I Lubricated with grease or anti-seize the first time; it's been at least 17 years. I replaced the rear rim once or twice, and bent the original Reflex clincher front in 2011. The nipples always turned fine so I reused them (apart from the pair I made trapezoidal with an incompletely seated spoke wrench straightening the bent front rim in a late night road-side repair), taking the opportunity to re-lubricate threads and sockets with anti-seize.

The Powertap/Velocity Fusion set I built in April 2014 is doing great, although I've only done 6000 miles on them so far so it's too early to tell and I haven't needed to true them.

I used zinc anti-seize on those (not the standard aluminum) which is the correct engineering choice because the zinc corrodes preferentially to the aluminum; although I suspect any grease which keeps water out is just fine.

While I'd conservatively recommend brass for spoke length and lubrication tolerance, I think most of the problem with alloy nipples is builder-error in those areas.
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