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Protruding Spokes

Old 09-03-05, 03:05 PM
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Protruding Spokes

I have rebuilt a wheel with a different rim but reusing the spokes. Some of the spokes are protruding pass the nipples ie 2mm too long. Do you file them ? Can you cut them using a wire cutter?
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Old 09-03-05, 09:03 PM
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File/grind/dremel cutting wheel if you feel you have to shorten them. Wire cutter would so deform that getting the nipple off would by a major hassle and would leave a nice cutting chisel edge on the spoke end to cut holes in the rim tape and inner tube unless you had flush cutters, which are uncommon.
2mm you might get by with two layers of good rim tape. Best bet would be to get new spokes that are 3-4mm shorter than the protruding ones. It is not that much money by mail order. There are spoke length calculators on the web.
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Old 09-03-05, 11:52 PM
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What kind of rim do you have? A double-layer one where the spokes & nipples are recessed? As long as they don't poke up above the upper-layer, you're fine, just lay down a rim-strip to cover the hole and that's it.

If it's a single-layer rim then you definitely need to trim them down. The quickest and fastest way I've found that takes about 2-minutes is to get out die-grinder and put on a thick cutting-wheel, about 4mm thick. Then just hold the wheel parallel to the rim, gently grind down each spoke to the top of the nipples and that's it! Lay down a rim-strip and you're good to go.

Other concern is that you may have bottomed out the nipples on the spokes. Did you end up with any nipples that simply won't tighten any more?
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Old 09-04-05, 12:35 AM
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I had the same problem when I tried to rebuild an old wheel, with its original spokes. I assumed that because it was the first time I tried wheelbuilding, I must have stuffed something up? If some of the spokes were too long, doesn't it mean that you didn't build the wheel properly?
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