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Can I dremel off the ends of spokes?

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Can I dremel off the ends of spokes?

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Old 11-28-09, 08:25 PM
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flammenwurfer
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Can I dremel off the ends of spokes?

I built a wheel and I don't know if my calculations were a bit off or what, but the end of the spokes are sticking out above the nipples. I've never built a wheel before but I would guess that would cause flats. Can I just dremel or file off the bits that are sticking out? Is it even normal or ok for them to be that long?
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Old 11-28-09, 08:29 PM
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yes...I have done it a few times my self...just be carefully not to grind on the rim or the rim ferule
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Old 11-28-09, 08:32 PM
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Yes. The ends of the spokes need to be flush with the nipples. Even when there's only a half turn of thread showing I file them flat using a small square file used parallel with the sides of the rim. Run a thumb over the nipple head to make sure no sharp edges are left. A Dremel with the right tool would probably be quicker. Then use a quality rim tape. Velox cloth types are very good at providing a bed for the inner tube.
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Old 11-28-09, 08:54 PM
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Thanks. I think I'm approaching the right tension. I'm just going by touch/ear. I'm just afraid I'm going to run out of thread before I'm at the proper tension. I'll see if I can get some pics of how far they are sticking out.
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Old 11-28-09, 09:05 PM
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Originally Posted by flammenwurfer View Post
Thanks. I think I'm approaching the right tension. I'm just going by touch/ear. I'm just afraid I'm going to run out of thread before I'm at the proper tension. I'll see if I can get some pics of how far they are sticking out.
What lacing pattern have you used? Years ago, on the first pair of wheels I built I had almost the whole spoke thread sticking out from the backs of the nipples. I was putting new rims on and they were the same size as the originals as far as I could tell. I worried about having enough thread so took the whole lot apart again and re-laced with four cross instead of three cross (which is how the original rims were laced) . The spokes and hubs were original, only the rims were new. Four cross lacing made things a whole lot better and in fact I'm still riding these wheels and only had to true them once, after about a month, when they had bedded in. They have been fine since. I've never had the same problem since, so my rims might have been a bit of an odd size?
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Old 11-28-09, 09:15 PM
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I once got the wrong number of crossings on one side of a wheel. Every other spoke stuck out 2 or 3 millimeters and was still loose. Took me a while to figure that one out.
Make sure you've got the right pattern then dremel away.
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Old 11-28-09, 09:59 PM
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I'm using a 3 cross pattern and that's what I used in the spoke calculator as well. I'm almost positive I've got the right pattern and everything. I double checked myself multiple times while I was putting it together.

Here is a picture of how much they are sticking out. The spokes are pretty firm now, but need to be tightened some more to have proper tension. I hope I can make these work. I don't want to have to order more spokes.
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Old 11-29-09, 06:30 AM
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Originally Posted by flammenwurfer View Post



Thats it? Back in the day I'd build wheels with whatever rins/spokes/hubs we had lying around the shop. This was back when spokes and nipples had alot of threads. Some wheels would have 5mm+ of spoke end sticking out. The easy fix was to either chisel them off with screwdriver and hammer or use a tool specificly designed for it. I'm fairly certain VAR made a tool for the task, it resembled a plier.
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Old 11-29-09, 07:06 AM
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Originally Posted by miamijim View Post
Thats it? Back in the day I'd build wheels with whatever rins/spokes/hubs we had lying around the shop. This was back when spokes and nipples had alot of threads. Some wheels would have 5mm+ of spoke end sticking out. The easy fix was to either chisel them off with screwdriver and hammer or use a tool specificly designed for it. I'm fairly certain VAR made a tool for the task, it resembled a plier.
Spoke Nipper. Hozan makes one too.
https://secure.actionbicycle.com/sag...&product=10944
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Old 11-29-09, 09:13 AM
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I'd say you nailed the spoke length, full nipple penatration is a good thing! We had a thin grinding wheel at the LBS when I was a wrench. Now days I just use a file and do it by hand (nudge, nudge, wink, wink).
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Old 11-29-09, 11:12 AM
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I came across a factory built wheel with even more threads sticking out before, I was kinda surprised to see something like that on a supposedly higher quality wheel (It was a double wall of course).
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Old 11-29-09, 12:44 PM
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I've been using a wheelset for 30 years that has filed spoke ends.
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Old 11-29-09, 01:11 PM
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Wurf,
Remind us of the hub, rim, and spoke length that you used..
Is this the AW-3 with CR-18, 26x1 3/8"?
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Old 11-29-09, 08:13 PM
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That's a cool picture. Looks like you did just fine. As I recall, spokes come in 2mm increments (or maybe that's just the brand I bought last time) so if you're within 2mm you're fine.
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Old 11-29-09, 10:41 PM
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Originally Posted by Mr IGH View Post
I'd say you nailed the spoke length, full nipple penatration is a good thing! We had a thin grinding wheel at the LBS when I was a wrench. Now days I just use a file and do it by hand (nudge, nudge, wink, wink).
Same here- we had one at the shop I worked at. The grinding wheel was narrow enough to get down between the walls of a steel Schwinn rim. It made it easy to build a rear wheel- just use all the same length spokes, dish on the stand, and grind off the excess.

One day I was doing this and the wheel slipped- I ended up with a gouge in my left index finger 1/2 way to the bone. It didn't bleed much, so I finished the day at work, then went to the ER to get it stitched up. They had to curl my finger back on itself to get the cut to close, so I had to operate with 3 fingers for several months while it healed and the finger stretched back out. It works fine now- and it's a beautiful scar.

(IGH- there's a used Rohloff hub on Feebay right now. Gonna get it?)
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Old 11-29-09, 11:08 PM
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Thanks guys.

This is a sturmey archer aw hub with an unknown brand of aluminum rim. Got a great deal on it and just measured it myself.

All that's left to do now is true it up, grind/file off the protruding spokes and wait for my tires to come.
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