I went to ride my Gitane yesterday, only to find the front tire flat. I pulled the tire off, inspected the tube, found a pinhole on the side nearest the rim (and the spoke hole closest the valve hole). Looking at the rim, I saw the Kapton tape had “failed” allowing the spoke tip through.

This is the first bike, IIRC, that I used Kapton on, in 2021. The choice of tire (GP5000 TdF) and the rim (no name, I must have lost any label during polishing) made mounting the tire just about impossible, and it was suggested at BF to remove the Velox tape in favor of Kapton because it is thinner. I used two layers, and I was pleased enough with the product that I use it on all wheels. This is the first I’ve seen of trouble.

(a) Is this a common occurrence? Does the product have a service life, and is a “consumable”? Not sure if three layers, instead of two, would make a difference.

(b) The tip of the spoke sticks up above the head of the nipple, made 1/8” but still down in the recess in the rim. With the old tape off, I see they all are. Should I be concerned and, if so, now what? I got out my Dremel, and put on a tiny stone bit, cylindrical and small enough to fit in the rim’s recess. Going in vertical, I tried, but made no progress on the spoke — but “drilled” a nice hole in the flat end of the stone. Just now, I checked Park Tool’s website and they do not list a STN-01 Spoke Tip Nipper to get down in there. Is there an alternative tool/method?

Perhaps I should ignore all this and just replace the tape, and ride and then expect to be notified of tape failure by a puncture flat every couple of years?