Not sure what you mean by weird nipple holes, it looks like part of the edge of the hole is missing ?

If this is the case - is it inline with the spoke ? ie. does the spoke point to the middle of the missing area ?

If it does then the only thing I seen like that is where cheap machine built wheels which have been built on a machine that isn't properly set up for the rim and the tooling has eaten away some of the box when the nipple was inserted.

If this is the case, the wheel shouldn't have passed QC.

Could it be a manufacturing defect of the rim itself ?

https://www.bikeforums.net/general-cycling-discussion/520919-am-i-ignorant-i-am-rude.html
Read it again. I actually said you were not a troll. I was wrong.

Well, I just wish you would make your mind up.....

so is the majority vote is that the rim is broken and needs to be replaced?

Mangled, yes.
Broken, no.
Mount your tire and go riding. Keep an eye on the area for cracks maybe.
I've done worse damage to the exterior of my rims on Toronto's unpredictable sewer grates. If you can't get it to stop flatting, show it to your LBS.

I would not trash a rim over that. Might take a paint marker and mark the tire where the spot is and even the tube. Next flat look it over pretty good. You could always fill that notch in with a little epox and sand it down, you would never know it was there...

I'd risk using it if it was a rear wheel, but not a front.

Damage like that can easily be the start of a fracture in extruded aluminium.

If you do use it, keep a close eye on it.

+1. JB Weld, thats the stuff.

If the nipple hole isn't round it's pretty much all over. JB weld or epoxy isn't going to fix it because that's a stress riser. It's like ripping a piece of cloth - once it starts, it tears very easily.

You can fix it right once and be done with it or you can fool around with it. If you decide to fool around with it you'll almost surely be replacing that rim sometime in the future.

No way is epoxy or JB weld going to improve the integrity of that rim.

It would simply be a filler.

Only ride on that rim if you are prepared to accept that it mght fail under hard cornering or hard breaking.

"It would simply be a filler"

And that is all you need. That is not a stress fracture, it is a dent you made using the wrong tool.

erm....."allegedly" ?

Ok, my comment was not even about the area around the nipples, it was about the dent in the rim. It was to be used as a filler as seagullplayer said. Just a filler.

Re-read posts 31 and 33.

I got another flat with a puncture in the same place yesterday. I didnt epoxy it yet ill admit... I had to ride it somewhere and instantly got a flat.

But do you think that the epoxy will stop the flats or is the goal just to make the bead not pop-out?

I have this epoxy... will it work?
https://www.devcon.com/products/produ...m?familyID=175

Oh yeah and:
all of my LBSs just want me to buy a new wheel... which i don't really want to do, they always want me to buy new stuff.

chico, I think the epox you listed would work, but I think a puddy type might be easier to apply. But if that is what you have I would try it. I did not see that is said it was sandable, but if it flows well you might not have to worry about that.

Is this the spot you are getting the flat? Or do you think the low pressure is the issue?

LBS always what you to buy something...

When you say 'in the same place' how do you mean ?

How do you know it's in the same place ?

Photo of the tube ?