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make your own db aero spokes
Posted: 3 Nov 2023, 7:16pm
by Brucey
over the years I have ended up with a lot of perfectly good 14G PG stainless spokes, in odd lengths. For the longest time I thought these were quite useless.
Then I had a good idea; why not turn them into DIY aero db spokes instead?
My proposed method is as follows:
1] use something like an old hacksaw frame to hold the spoke taut using suitable end fittings.
2] use width of cut as a proxy for depth of cut on the round cross section and carefully 'shave' one side of the spoke using AG+cutting disc,
3] feather the edges of the cut so as to make a nice aero profile
4] turn the whole thing over and repeat the above steps on the other side
5] use something else [eg a Dremel tool fitted with a drum sanding head] to abrade the spoke lengthwise all over.
6] polish to suit
7] an additional step is to hammer the spoke between steps 1&2. I think the each hammer blow will cause the spoke to lengthen slightly and that subsequent grinding will erase any evidence of hammering.
I think that if you do step 7 you can add several mm to each spoke.
i don't expect such spokes to be quite as strong as factory spokes but I would expect them to be strong enough for a typical front wheel. This method obviously won't suit anyone trying to make a living by building wheels but I would expect to be able to do a wheel's worth in about half an hour and that may be acceptable to a lot of people who build for other reasons.
Re: make your own db aero spokes
Posted: 3 Nov 2023, 8:02pm
by Cyclothesist
...Checks date (no it's not 1/4).
I'd love to see a video of this and SG / PSG
Re: make your own db aero spokes
Posted: 18 Nov 2023, 1:56pm
by cyclop
Brucey wrote: ↑3 Nov 2023, 7:16pm
over the years I have ended up with a lot of perfectly good 14G PG stainless spokes, in odd lengths. For the longest time I thought these were quite useless.
Then I had a good idea; why not turn them into DIY aero db spokes instead?
My proposed method is as follows:
1] use something like an old hacksaw frame to hold the spoke taut using suitable end fittings.
2] use width of cut as a proxy for depth of cut on the round cross section and carefully 'shave' one side of the spoke using AG+cutting disc,
3] feather the edges of the cut so as to make a nice aero profile
4] turn the whole thing over and repeat the above steps on the other side
5] use something else [eg a Dremel tool fitted with a drum sanding head] to abrade the spoke lengthwise all over.
6] polish to suit
7] an additional step is to hammer the spoke between steps 1&2. I think the each hammer blow will cause the spoke to lengthen slightly and that subsequent grinding will erase any evidence of hammering.
I think that if you do step 7 you can add several mm to each spoke.
i don't expect such spokes to be quite as strong as factory spokes but I would expect them to be strong enough for a typical front wheel. This method obviously won't suit anyone trying to make a living by building wheels but I would expect to be able to do a wheel's worth in about half an hour and that may be acceptable to a lot of people who build for other reasons.
I hesitate to question such an authority but a)are you being serious?Are you playing devils advocate to see if anyone would actually query this and say why?I think probably not.More like a theoretical train of thought as to whether it,s possible.
Re: make your own db aero spokes
Posted: 18 Nov 2023, 4:12pm
by Audax67
36 spokes later, apply for membership of the local obsessives' self-help group.
Re: make your own db aero spokes
Posted: 18 Nov 2023, 4:47pm
by Brucey
cyclop wrote: ↑18 Nov 2023, 1:56pm ............are you being serious?......
yes perfectly serious; tell me one good reason why it is not going to work
Re: make your own db aero spokes
Posted: 19 Nov 2023, 10:32am
by Cyclothesist
Probably because after a lot of effort you'll have a set of wonky deformed spokes of dubious strength, variable length and thickness and which in addition to being a safety hazard you wouldn't want to be seen dead with on your bike. I did enjoy the hilarious idea though, it's one of the best humorous cycling posts ever!
Re: make your own db aero spokes
Posted: 19 Nov 2023, 12:16pm
by Brucey
what is all this talk a of 'safety hazard'? IME a 36h front wheel is completely over-engineered and the 'risk' is a broken spoke. Jeez......
Re: make your own db aero spokes
Posted: 19 Nov 2023, 12:30pm
by rareposter
Brucey wrote: ↑18 Nov 2023, 4:47pm
yes perfectly serious; tell me one good reason why it is not going to work
I'm still trying to work out if you're joking/trolling for laughs or actually serious.
Re: make your own db aero spokes
Posted: 19 Nov 2023, 1:22pm
by Brucey
talk of casting pearls before swine, I dunno.....
Re: make your own db aero spokes
Posted: 19 Nov 2023, 1:31pm
by cyclop
Brucey wrote: ↑18 Nov 2023, 4:47pm
cyclop wrote: ↑18 Nov 2023, 1:56pm ............are you being serious?......
yes perfectly serious; tell me one good reason why it is not going to work
Instinct,common sense,tiny marginal gains,I,d rather clean my chain(sensible),I,d rather watch "I,m a celebrity........."Ok the last one goes beyond the pale.I suppose as an exercise for engineering students it has it,s merits.Maybe even a punishment for engineering students who question the merits of a,seemingly pointless procedure.In answer to your question,because I bet very,very few people have your knowledge,confidence,skill ,equipment or patience to even remotely consider doing this.Also,it,s barmy.This is the subjective answer,but,of course,you didn,t actually ask that.Of course it,s possible with the right tools and skill set.
Re: make your own db aero spokes
Posted: 19 Nov 2023, 1:52pm
by jb
I have an old gas pipe frame, I reckon with careful use of a file to make it a lightweight racing machine, who needs double butted tubes pah...
Re: make your own db aero spokes
Posted: 19 Nov 2023, 4:38pm
by fastpedaller
On reading the OP, I immediately thought "Brucey will be along soon to advise them not to do it".........
Brucey, April 1st is a long way off!
Re: make your own db aero spokes
Posted: 19 Nov 2023, 4:50pm
by Brucey
jb wrote: ↑19 Nov 2023, 1:52pm
I have an old gas pipe frame, I reckon with careful use of a file to make it a lightweight racing machine, who needs double butted tubes pah...
you may well jest but you are closer to the truth than you think.
Re: make your own db aero spokes
Posted: 19 Nov 2023, 4:53pm
by fastpedaller
Brucey wrote: ↑19 Nov 2023, 4:50pm
jb wrote: ↑19 Nov 2023, 1:52pm
I have an old gas pipe frame, I reckon with careful use of a file to make it a lightweight racing machine, who needs double butted tubes pah...
you may well jest but you are closer to the truth than you think.
Ir may well end up light, but won't be (as) strong
Re: make your own db aero spokes
Posted: 19 Nov 2023, 10:30pm
by Cyclothesist
fastpedaller wrote: ↑19 Nov 2023, 4:53pm
Brucey wrote: ↑19 Nov 2023, 4:50pm
jb wrote: ↑19 Nov 2023, 1:52pm
I have an old gas pipe frame, I reckon with careful use of a file to make it a lightweight racing machine, who needs double butted tubes pah...
you may well jest but you are closer to the truth than you think.
Ir may well end up light, but won't be (as) strong
But after all that filing you certainly will be!
