I have my Trek 600 all duded up with 1993 105, with 7 speed brifters. The wheelset came from a 90's Master TG and is a era correct(to the group) 105 hubs and Sun Mistral rims in Ultra hard dark anodized finish. Now, the Master popped a rear spoke on the first ride after the refurb, and I replaced it with another wheelset I had in the stash. Fast forward a year or so later, and I decided to use the wheelset on the 600. On the first ride longer than 20 miles it popped another spoke. I thought it was just a fluke, and replaced it. Well, on the very next ride after about 8-9 miles in....POP!

I now realize this is the third spoke on this back wheel to break, each in under 20 miles. The hub looks fine, although there is evidence it was in a previous build, with spoke marks going in other directions than the existing ones. I am left wondering if someone tried rebuilding this wheel before, and if they did, was it to try and remedy this very problem I am having? The only spokes to have mfg marks on the hub end, are the ones I've replaced.

So is it bad spoke tension? Inferior spoke quality on the rebuild? This wheel is cursed?

Honestly this is the one single wheel I have ever had this kind of problem with. Have I just been lucky until now? I REALLY want to ride this bike this weekend, but the prospect of replacing 33 spokes after working on bikes all day long has me a little weary. I should just suck it up and do it, right??,,,,BD

Are the spokes breaking on the drive side or non-drive side? Have you check spoke tension? Also do a visual check on all the spokes? Check for bent or broken axle. Is you rear derailleur adjusted properly?

The hub and rim are just that, and I assume you know what is, and is not, reasonable spoke tension, so it seems to me that the spokes themselves are the unknown quantity: I would re-lace the wheel with name brand spokes -( or get a different wheel.)

Alloy or brass nipples?

Neal

I vote for relacing the rim, preferably with double-butted spokes for extra resilience. They are springier in the middle and less likely to snap under stress.

If the hub has grooves on it from being laced previously, it is best to follow those grooves. Lacing the other way will stress the hub flanges and make them more likely to break.

My rule, learned through too many times of NOT listening to The Rule: When the first spoke plinks in a 20+ year old wheelset, relace it with new ones.

Better in the long run than doing them one at a time or -even worse in my book- having multiple re-truing sessions out on the road when the nest one plinks so you can get home.

Brass nipples and 36 spokes, it is a 7 speed cassette not freewheel. The axle and derailleur are fine. It's done it on two bikes, so I imagine it is junk quality spokes. Two drive sides, and one non drive side have broken. They break right at the hub, about a 1/4" from the head, just past the bend. I guess I really don't have a choice. It's going to continue popping spokes one at a time until they're all replaced, huh? I was afraid of that. Oh well.,,,,BD

Spoke tension, rather than spoke quality, is to blame. If you replace them one at a time, and correct the spoke tension now, they may stop popping; or maybe not. The old ones, and maybe (some of) the new ones are already fatigued to near the breaking point. I'm afraid you have to replace them all, and get the tension right this time.

I know I'm in the minority here, but I don't believe you get a better wheel by paying extra for a more expensive brand of spokes.

Almost certainly spoke tension. Could be too low (most likely), uneven (pretty likely), or too high (least likely, I think).

At a minimum I would detension all the spokes and tension them up right. This may be problematic if ALL of the spokes do not turn easily in their nipples. At a maximum, I would relace it with new spokes.

Messing with wheels is a necessary part of this hobby, so if you have not gone their yet, this is the time to do so.

jim

It got built, and I rode the bike home from work. So far so good. Wish me luck tomorrow.,,,,BD

Well here I am right before the start. The soggiest 40 miles I've ever ridden. The wheel got a little out of true on the ride home from work, but after a quick home true it stayed straight through the entire ride.,,,,BD

And nope, didn't lose a single spoke.

https://www.flickr.com/photos/6000004...n/photostream#

Were the spokes reused?

How do you ride with an umbrella? and don't say practice.

Your 600 is sharp and looks immaculate. I am in the middle of building up a 560, after the first few rides on the original components and I liked it a lot.

Nope, used new DT spokes, and nope, didn't ride with an umbrella. That was just to show it was raining. It did stop raining for a half hour or so during the ride though? Raining and cool this morning, so I am driving.....sigh. My Pearl Izumis need some down time, and nothing in my stable has fenders at the moment. Not any I'd ride in the rain anyhow.,,,,BD