Wheelbuilding / Wheel Building / Wheel build help

All:
Was out riding yday, friend whose wheels were built by me had sudden spoke breakage. He was not particularly kind to these wheels, saw him bump the bike down kerbs at least twice in the preceding 30 miles, but not totally abusing them or anything.

Spoke broke at the bend. Build is DT Alpine III on Open Pro, Chorus 9sp hubs. I did have to file a tiny bit at the holes to get the spokes in.

We did emergency bodge re-true by the road. Will have to repair, any starting advice on how to get this wheel sorted?

Why would spokes break at the bend?

@graunch Sam at LMNH is building me a Shutter Precision PV-8 on a HED Ardennes. Have a word with him, his advice is very sound.

Why would spokes break at the bend?

It would be mysterious if they broke anywhere else. The bend is never perfectly supported, so as the spoke stress cycles, the bend gets straightened and then springs back, eventually leading to a fatigue fracture.

Thanks tester. I guess I'm perplexed as the wheel hasn't really seen alot of use.

I do recall my spoke tension wasn't very even (per side), primarily because the Open Pro just was all over the place after initial tensioning and I guess I had to vary it somuch to get it to true.

Might persuade the rider to switch to Sputnik or archetype or something solid like that.

I need to remove the M10 freehub from an Aksium Race and fit it to a Cosmic Carbone SL.

Can someone confirm compatibility? The spare part number is the same.

The Carbone are QRM+/SL, so I just need this tool to remove/refit the freehub?

TIA.

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Bearings are cheap. You've done the hard work so you may as well replace them all. Is there a reason why you want to replace the axle?

If your rim is not round I think your building in problems. I had a dodgy VO rim and it was a pain to get built but seemed solid once done. It got pranged and went wildly out of true and repairing was impossible - I think because spoke tension was not perfect initially. Other (rounder) rims have had similar repairs easily.

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Thanks, I thought the axle needed replacing because it looks like there is some strange wear or maybe the bearings are partly stuck to it? What do you reckon?

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Looks like you've got the inner race of a cartridge bearing still on it.

Why would spokes break at the bend?

It would be mysterious if they broke anywhere else. The bend is never perfectly supported

Just after lacing, while everything's still loose, it's worth flexing all the head-in spokes hard inwards against the flange - helps get them aligned a little better and improves the support a touch.

At least, that's what Jobst tells you to do.

Thank you, I will

ola, my front wheel was a bit warped in a polo 'accident', so I'd like to replace the rim. its a cheap Mach 1 Neo Disc 36h, but I can't find it anywhere for sale to even check the dimensions to see what I can use instead (i'd like to re-use the spokes).
It looks a bit like a rigida taurus, but can anyone suggest anything else?

Just after lacing, while everything's still loose, it's worth flexing all the head-in spokes hard inwards against the flange

If the forum had a proper search function, I'd find the post where I said exactly that. It certainly improves the lot of the outbound spokes, but @specialist reckons it's nearly always the inbound spokes which break.

Oh, I didn't think it was new wisdom - just that it bore repeating on the same page as @Skülly 's question

@mdcc_tester @jsabine
Cool, thanks you lot, certainly I didn't use a lot of force to flex the outbounds over the flanges, which I realise now was a mistake. Was chatting to a wheelbuilder the other day who mentioned that in the case of Alpine III, I should have used a punch to ensure a nice snug fit for the spoke heads before adding tension.

I'm learning as I go.

My sun cr18 rims are on the way out. Hubs n spokes are still fine. I can't get them in UK in 36h...getting wheels on ebay may only be slightly dearer but I don't like dumping things.

So new rims of another make it is, if that works.

Can I trust the erd of sun? Anybody used their rims?

Like an idiot, I have managed to strip the thread out of one of the rotor bolt holes on my hub on my disc brake wheelset.

Is the hub now a write-off, or is there anything I can do to fix? Or just run it with 5 bolts?

5 bolts will be fine. XC racers have been running 3 bolts for years.

Thanks - I was leaning towards that option but a chap in a shop gave me the full "I couldn't possibly recommend that Sir, but it's your face if you want to take the risk" treatment which has got me spooked.

is there anything I can do to fix?

Helicoil
http://www.amazon.co.uk/Draper-Expert-Metric-Thread-Repair/dp/B008YFZ7PG

wow - some kind of witchcraft!

I suspect three or five bolts would be fine but if it was me I would use a Helicoil as mdcc_tester suggests.

I used M13ii rims for my 27" wheels, as there's not much choice for 27". The ERD was spot on.

OK, tx!

I found them now, SJS does them. At "£££ duur" alas ;)