• I think breaking at the head/bend suggests movement and 'fretting'.

    The only time I've used spoke head washers has been when building coaster brake hubs as they have really large spoke holes. Done a couple and given them dogs abuse and never had any breakages.

    I just used the same spokes I normally would (Alpina, Sapim race, that kind of thing. Cheap, butted spokes). I probably just didn't think of using thicker spokes but my ack of issues would suggest they aren't really needed.

  • +lynx most if not all hub motors spoke holes are 2.3 or 2.6mm IIRC so you'll require the washers.

    Would have gone for 13 or 12 gauge spokes but that'll be a custom order which will be spendy, so washers it is.

  • most if not all hub motors spoke holes are 2.3 or 2.6mm

    So, just like most normal hubs then🙂

    I'd probably use DT Alpine III or the like for anything load bearing, they're 2.3mm at the head/bend, which is about a third more cross sectional area than 2mm spokes.

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