harshbarj

I broke a few spokes on my 1980's dutch import bicycle and needed to get the wheel rebuilt. The LBS has told me it is going to be impossible to fix outside of a special order because the spokes are too long.

The shorter side spokes are ~290mm, and I guess the other side is about 310-320mm. I say guess because I don't have the wheel at the moment. The LBS has it waiting on my decision.

So what I need are 2.2mm spokes that are 320mm in length or longer (as the LBS can cut them). Looking around I can't find them, and the price being asked at the LBS puts the rebuild at more than a new wheel would cost ($175). Normally it costs me $115. They also said they would have to use thinner spokes, which is not acceptable on a utility bike.

The hub is a Sturmey Archer AB 3 sped hub with a 90mm drumbrake.
Sturmey-Archer Heritage :: History

Thanks for any suggestions.

fietsbob

2 cross so you have a shorter distance ... whats wrong with 36 2mm?

79pmooney

It wouldn't cost you anything to contact Wheelsmith and see if they can help. Or Phil Wood. I am sure there are others that can do custom runs of spokes.

Ben

harshbarj

More likely to break. Thicker spokes are better. It's not uncommon for me to haul 100-200 lbs. My other utility bike uses I think 3mm and I have hauled up to 300 lbs with that. Going on 5 years with that rebuild.

The length given is an actual spoke measurement. I have one spoke here. The longer side is an educated guess.

Abe_Froman

I really don't believe the drive side requires 320 mm spokes...unless the thing has like a foot of dish. Even an 11 speed bike with big dish only has ~2mm difference between spoke lengths. I think the bike shop is messing with you.

Err, unless the flanges are different sizes. Is it possible that is the case?

dabac

What size rim are you using to need custom spokes?
Another option is to make an adapter plate.
A wide ring out of 3 mm sheet metal. Screws onto the flange to effectively widen it.
Takes some time, but can be done with hand tools.

fietsbob

my S-A drum brake hub is 27 years only broke 1 spoke, DT 2mm..

looked at motorcycle shop's suppliers ?

Retro Grouch 

That's what I was thinking. That sounds like a lot of difference in spoke length side-to-side.

Abe_Froman

Yeah. Maybe a lazy bikestore that didn't have anything longer than 290...so they just said sure go buy 320, we'll charge you to cut them down and rebuild the wheel?

Retro Grouch 

I'm thinking more likely they just measured wrong. That's easy to do if you don't remove a spoke so you can make an accurate measurement. If they're thinking they are going to cut it to length, they were probably just making a preliminary estimate. If in fact the spokes really are longer than 310mm, that might indeed be a "pain" to source.

harshbarj

The AB hub has two different size sides. The drive side is small, while the other side has an integrated 90mm drum brake.

An example of an AB hub. The 290mm spokes I have are from the larger drumbrake side.

harshbarj

At this point I'm going to drop by and talk to them. See if they can actually give me the spoke length they think is needed and perhaps suggest removing a good spoke from each side to measure.

Retro Grouch 

That's definitely what I would do. One accurate measurement is worth 1,000 assumptions.

What size is the rim? If the correct spoke size for the drum brake side really is 290 mm, a 310 mm spoke (easily get-able) would be not quite an inch longer. Just eyeballing that photo, that looks pretty close to me. 320 mm spokes might be a lot harder to find.

Good luck!

SkyDog75

Sapim 14 gauge (2.2 mm) stainless steel spokes are 25 cents each from Dan's Comp, cut to whatever length you need. Give 'em a call and see if they can do spokes that long.

Bill Kapaun

I think the hub I used is basically what you have. I used a "possible" 27" rim with an ERD of 622.
A X3 gives a "shorter" spoke of about 291. Note the longer spoke is only 5mm longer.

Also note that when going X4 the longer spoke is on the opposite side.

Blackstrida_A_

Regarding extra long spokes I wonder that nobody mentioned 36" wheels like that from Truebikes, Cokercycles or the Qu-Ax Gentlemanbike.
With an estimated ERD of ~ 850 mm their spokes have to be at least ~ 410 mm I guess?

Retro Grouch 

That's a good point. Somebody obviously makes spokes that long, I just don't know where to source them.

Blackstrida_A_

Unicycle is the keyword - here a source for spokes up to 700 mm:
https://www.unicycle.uk.com/unicycle-parts/spokes.html