Zipp wheel rebuild question
 

hey all
i have a zipp 404 that is to be rebuilt for a customer

the reason for the rebuild is that one of the spoke flanges cracked and is now unusable. this is the straight pull hub.

the customer had an older, regular spoke zipp hub that he wanted laced into the wheel instead of buying a replacement for the straight pull. the older hub that i am to use is a zipp hub but there are no other markings. the center section is carbon, the flanges are silver, and the freehub body is black. i have almost no experience with zipp products so im not sure how old this hub is or anything else about it.

my shop mgr took the measurements for the new spokes and arrived at a length of 254mm. sapim cx-ray spokes were ordered.

when i was given all of the parts needed, i quickly learned that the sapim spokes do not sit flat on the hub flange. this is true on both the inside and outside facing spokes. it is as though the heads on the spokes need to be bent slightly different.

does anyone have suggestions for other spokes with similar features that would work with these hubs?

thanks!

*the hub is a '93-'95 zipp 295 hub according to paperwork i have with the repair

Sorry it took me a while to get back to you on this, our head wheelbuilder that was around back in the day was out of town. During the production run of the 295 hub, we used either the Wheelsmith bladed spokes or the Union titanium spokes.
Hope that wasn't too late to help. PM me if you need other info.

I remeasured the rim and hub and found that the spokes were in fact too long. I reordered the correct size (still sticking with the Sapim CX-ray, and though presented the same initial problems (Shoulders of bend not laying flat against flange). However, after getting the spokes to about half tension (35-45 kgf) they began to seat correctly and made for a very easy build overall.