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Front axle does not fit into fork ends.

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Front axle does not fit into fork ends.

Old 05-31-18, 06:04 PM
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Front axle does not fit into fork ends.

So i recently bought a 2008? Jamis Sputnik frame with the original BB and crankset. My plan was to move all of the parts from my Zycle Fix Prime over to the Sputnik, however I quickly found that the front axle is too thick to fit into the forkends. I want to avoid any filing (really don't trust myself to not go crazy with the file), but the part that perplexes me is that i thought that at least on newer bikes there is a fairly standard axle diameter of 9mm in the front and 10mm in the back, though I don't really know ****. The fork ends appear unbent, as does the axle, and there is no excess paint in the grooves. They simply aren't compatible.

I did some searching around here and it seems to be an issue with older vintage bikes. I guess my question is what my next move should be? Do I need to purchase a new wheelset? Can I simply swap out the axle?

Thanks in advance for any input!
(sorry, I'm a noob &#128531
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Old 05-31-18, 07:01 PM
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I experienced the same thing. Go easy on the file

Despite years of experience with a home machine shop using lathes and mills and hand tools, I used a file too aggressively and ended up with an axle that fit too loosely and was not parallel. It wasn't enough to cause poor handling or tracking, but I felt bad about doing hack work on a noble old fork. Proceed very gently and with caution. You can't put back what you over remove, short of crazy welding and re machining.
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Old 05-31-18, 08:09 PM
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Originally Posted by InfiniteJester View Post
...The fork ends appear unbent, ...
A few good measurements could confirm this, as well as the axle diameter, which could be helpful in diagnosing your issue.
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Old 06-01-18, 02:58 AM
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Do some measuring and establish how big is the difference.

If you want, you can do the filing on the hub axle (two flats across each other to make the axle thiner in one direction. This will make the axle fit only in that position! (make sure the flats align on either side). -just shave the top part of thread and it should be more than enough. Or even better, and safer and easier : file the dropout a tad (if you have standard 9mm axle it is really beneficial to file the dropout to make it fit any standard front 9mm axle)

I did file the axle for a fixed gear front hub where the axle was a rear axle at origin of 10mm.. i did not want to file the fork dropout to 10mm, so i filed the axle to 9mm (in two opposing flats each side as i said)
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Old 06-01-18, 08:29 AM
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besides having a few differing axle diameters (and then the drop out slots dimensions to fit) there's also tolerances of dimensional control (usually more seen with the drop outs) and after construction finishing changes (excessive paint in slot) that all contribute to an axle's fit within a drop out. As mentioned a measurement says a lot more then a simple look at does. Andy
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Old 06-01-18, 08:54 AM
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generally 9mm is a front axle (except solid axle, american cruisers, etc.) 10mm rear ..

Almost nobody seems to measure first then post,... like we can guess...
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Old 06-01-18, 11:12 AM
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Quite a few fixed gear/singlespeed wheelsets have 10mm or 3/8" front axles
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Old 06-01-18, 01:27 PM
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It's not a matter of your 2008 bike being older or new than the other. It's just a matter that they don't use the same size axle. You can easily find the correct size axle for bikes made well before the 1980's.

You might be able change just the axle and cones and lock nuts to make the other wheel work. But some will and some won't. Don't know what you have.
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