Sturmey Archer hub flanges

[rjb]

What do you think of this mod. Match your AW hub to any rim by fitting a flange with the correct drilling.
Looks like copper rivets.
Copied from a Facebook thread.

[Carlton green]

What do you think of this mod. Match your AW hub to any rim by fitting a flange with the correct drilling.
Looks like copper rivets.
Copied from a Facebook thread.
FB_IMG_17654903301751070.jpg

Though I can envisage applications I’m not certain that this isn’t a solution looking for a problem, These adaptors won’t be cheap to buy and they’ll take a time to fit too; in terms of being cost effective that’s not a good start. I wonder about the number of crosses to use in spoking, less than normal as otherwise the rim to spoke angle becomes excessive?

iirc, in case needed, there has been at least one thread about lacing wheels where rim and hub have differing numbers of spoke holes.

[Brucey]

oddly enough I have been thinking along similar lines, being no stranger to making and fitting my own hub flanges. I would argue that the copper rivets are complete overkill, because any loads are likely to be shared; Al rivets or an adhesive bond would probably suffice.

My proposed route would see ~3mm flanges made by SGing ~4mm thickness Al. This 'extra thickness' does two things;

1) it makes it easy to incorporate a 'belt and braces' joggle feature, allowing complete functionality, even in the event of joint failure. This design has been used with previous (welded) flanges, but ought to work equally well with riveted or bonded flanges.

2) a small groove can be made at the new spoke drilling PCD. This helps with accurate hole placement, even in the absence of a dividing head.

Again this feature has been used previously. After the flange has been drilled for the spokes, the groove can simply be machined away, leaving the flange the correct thickness. IME tapping SA flanges M3 is very easy indeed, allowing you to go belt, braces, and another belt, by including a few M3 screws in there, too.

[rogerzilla]

36h and 28h AW shells are easy to get, and most A-series internals can go into them, so it's only 32h wheels, or maybe that problem 40h ASC you've been itching to try, that would benefit.

[Brucey]

there are several different ways by which a 32h rim can be built onto a 40h hub. None are particularly difficult. However, Al (thick/soft) is much preferable (in many respects) vs. steel for a flange; it is certainly more compatible with modern spokes; I have even resorted to using two washers per spoke; Al flanges would have been considerably easier/better.