Reuse old spokes?

Linedog · Oct 30, 2024

So I wanna put my 2 speed kickback on my Heavy Duti. I would like to use the same spokes but I know they will need to be shortened. Can I measure then cut and thread them to work? Not trying to be cheap but looking to keep the same patina of the spokes on the front. Photos added cuz we all like them.

idiotboy · Oct 30, 2024

if the original wheel was laced cross 3, try the 2 speed with cross 4, I did that once and it worked with the existing spoke length

Linedog · Oct 30, 2024

Oh heck thanks !!!!!

DesmoDog · Oct 30, 2024

Most people don't have access to the tools needed to properly rethread a shortened spoke - the threads aren't cut with a die, they are rolled so they're stronger. The cross 4 pattern sounds like a great solution if it works out.

rickpaulos · Oct 30, 2024

There have been 2 main tools on the market in the past 50 years for rolling spoke threads.

Hozan hand crank model. Different size rollers for different diameters of spokes. Run about $150 to $200 these days. I have one and it's rather tedious to do a whole wheel of spokes. I mostly use it for single replacements. I've tried using it with a cordless drill to keep from wearing my skin through. Padded gloves are a good thing to use. Has a little difficulty with 2.0 stainless steel spokes.

Phil Wool spoke cutter and roller. Very nice but they run about $4000 to $6000 now. On my wish list.

There are a couple of newer models, Mitsumi (?) and I don't remember. Those run $2000 - $3500.

I still rebuild wheels (over 2,000) quite often using used spokes. But I generally won't used zinc plated spokes. Just too drab looking. Also I rarely ever use black spokes. Most of those are "mystery metal" under the black coating and are very weak. The other no-no is using steel spoke nipples. They will rust and bind up. A magnet is the best way to determine if a nipple is steel, aluminum or brass. Most old school brass nipples are nickle or chrome plated so they look pretty much the same as steel. The old Schwinns used longer spoke nipples, about 3/4" long so those are more tolerant of spoke lengths that aren't just right. An angle grinder handy for trimming long ends off after a wheel is tensioned. It's amazing how many factory built wheels have had the ends ground off. Of course most of those were built before the www. The 1970s Sutherlands spoke charts were pretty inaccurate. Modern computers do the math much better.

There are several spoke length calculators on the web. Best bet for determining what lengths work. Some will show you all X options.

rickpaulos · Oct 30, 2024

Just reread you post. The Schwinn "Heavy Duti" came with thicker spokes. The hubs had larger spoke holes, the rims had larger nipple holes. A regular size spoke can pull right through the hd size holes. Schwinn has different part numbers for the hd rims. I don't have a .105 or .120 die for my Hozan spoke roller. I would think Bendix made the yellow bands hubs with 2 spoke hole sizes for Stingrays and the Heavy Duty/Twinn. Try 1 spoke to see if it will fit in the hub before taking the old wheel completely apart.

I drilled out a hub one time so I could use over thick spokes in it. I sure don't recommed that. The hubshell was chrome plated hardened steel and I went through about 20 drill bits. The holes were all chipped up. The Bendix hubs have the bearing races as part of the shell so the steel will be very very hard.

Wildcat · Oct 30, 2024

idiotboy said:
if the original wheel was laced cross 3, try the 2 speed with cross 4, I did that once and it worked with the existing spoke length

I found some info on the CABE about this very topic, single speed to yellow band 2 speed.
The yellow band diameter is 1.06 inches wider than the usual one speed hub. Using that info on a spoke calculator I figured this:
With a 26" rim, your present spokes are about 258mm at 3 cross. Guessing the flange diameter at 60mm for your one speed, and 86mm for the yellow band..
To lace up the rim to a yellow band hub at 3 cross, the spokes would be about 253mm, 5mm shorter.
To lace the yellow band at 4 cross would need spokes 266mm, a lot longer than your present spokes.

This is guessing, I would need to measure your hubs, rims, and spokes, then use this calculator to see what would fit.

https://www.prowheelbuilder.com/spokelengthcalculator

edit: I just read rickpaulos post, the spokes may be too thick, so they won't work, but you may find a wheel from an old 26" mountain bike or beach cruiser that will have similar looking spokes that will be a match in patina to your front wheel.

Reuse old spokes?

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