azza_333

I was planning to have my wheels rebuilt with some shallow carbon rims for a new bike build, but my wife mention wanting the old wheels for her bike, so I am most likely going to have built a new wheelset.

The new wheels are intended for road/gravel bike packing, and light touring. It will also double as my bunch ride bike for weekends. As for the load of the bike when bikepacking/touring 210lbs or 95kg (Bike 10kg, Rider 70kg, Luggage 10kg, plus an additional 5kg fudge factor)

I have a few questions though, given my intended use:

- My old wheelset that my wife wants has 7 year old DT Swiss 240 hubs 32h, do the flanges have a fatigue life or anything like that? I have seen a few pictures online of flanges breaking. Even if I consider reusing them for me with new rims, I would want to know the flanges are 100%.

- Since DT SWISS don't make 32h 240 hubs anymore would 28h be solidly reliable for my use?

- I would get a profession wheel builder to build them, so I will go with what ever he recommends, but I am just wondering, is 3 cross the strongest for a 28h wheel?

- I have read that deeper rims are stronger, I am considering 3 different rims 30mm, 50mm, or a 36mm rim that has an Asymmetric rim profile. I was leaning towards the 30mm since its light, but I wouldn't be against considering 50mm for bunch rides. Is there a large strength difference between the rim depths? And is spokes ripping nipples through carbon rims a serious issue?

- Spoke selection, again I will go with what ever the wheel builder recommends, but I would rather have an idea ahead of time, would I need something as beefy as DT Swiss Alpine III spokes, to make a 28h wheel reliable for me intended use? or would something lighter like DT Swiss Competition spokes be strong enough? I might consider a bladed spoke like DT Swiss Aero Comp if I go with the 50mm rim depth.

Thanks in advance for feedback.

JohnDThompson 

For loaded touring, I'd find a hub/wheelset with a sensible number of spokes, 32 at a minimum, 36 preferable. Unless you're riding in competitive events, I wouldn't bother with superlight/low spoke count stuff. Instead, spend your money on getting a hand-built/tensioned wheelset from a reputable wheelbuilder, who can assess your needs and recommend appropriate components for the build.

Andrew R Stewart 

As is usual with wheel questions there's a big "shade of grey" range, thus few black and white answers. Andy

pdlamb

Only flanges I've seen break were a couple of new hubs (<6 month). If they were forged correctly, they'll last a long time.

That said, next time you wash your bike, give the hubs a close look.

cyccommute 

There probably is but the length of time is likely beyond what any one person could put on them in a lifetime. I have hubs that are close to 20 years old and have 25,000 miles on them. That’s a lot of tension/detension cycles.

That depends on your use and your tolerance for broken spokes. You might be able to use them and never break a spoke. On the other hand, you might start popping spokes like Orville Redenbacher pops corn. A way to make the wheel more reliable with fewer spokes is to use stronger spokes. DT Alpine III spokes are stronger and make for stronger wheels. This article explains why using triple butted spokes is a good idea. Personally, I don’t use less than 32 spokes but if I did, I’d use Alpines.

I should work but I doubt that the cross pattern will make much difference.

“Stronger” how? Strength of rims is widely overblown. The rim does little to make a wheel “strong”. The rim is there as a vehicle for holding the spokes and a convenient place to put a tire. When it comes to wheel strength, the spokes do all the heavy lifting (and get none of the credit). Think of it this way: if a rim is damaged or wears out, is the wheel finished? Probably not. It’s not difficult to replace a rim. But break more than a couple of spokes and the wheel is well on it’s way to the scrap yard.

Should have read ahead. What spoke you use depends on whether you value saving about 100g for the whole wheel set or you want wheels that are more durable. I always choose durability.