Broken spokes on 36er GUNI
Here are my 2 centsā¦
The loads on the spokes of a 36er are substantially higher than smaller wheels, simple function of the lever. And when you increase the speed due to the geared hub, the loads multiply to the point where the spokes are continuously over stressed until they unlimately break.
Now here are a list of actions that can be taken to reduce breakage:
First, you need to start with quality spokesā¦chinese spokes use junk steelā¦I do not trust any spokes without a reputation for proven quality. If I start getting spoke breakage on my 36er, I am going to have DT Swiss cut me custom spokesā¦
Second, once the wheel is built, spoke tension becomes absolutely critical. The longer the spoke the more often it will need to be retensioned, because as the spoke is ridden, it will continuously stretch, get longer. Find a bike shop with a tensiometer, and monitor the spoke tension every 250, 500, 750 etc. kilometers. At the beginning, the spokes will stretch more and will need to be retensioned more often. In my experience, after you build a wheel, especially a 36er, the wheel will need to be retensioned (retrued) after every few rides, until fully stress relieved.
Third, washers between the spoke heads and hub is a solution that has been discussed in previous posts. However, one detail that was missed is counter sinking the spoke holes in the hub to match the head of the spoke. The reason for brass washers is the friction between the spoke head and hub is substantially reduced. The washer serves as a bearing.
Fourth, wrapping the spoke intersections with wire and soldering the wire wrap has also been discussed in a previous post.
Items, three and four would be considered old school wheel building. These methods were common for race bikes, road, mountain and particularly track bikes up until the late 90ās. In 2009, the materials and hub, spoke and rim designs for race bikes have substantially improved to the point where these methods are not needed or cannot work anymore.
There is a great book The Art of Wheelbuilding: A Bench Reference for Neophytes, Pros & Wheelaholics (Spiral-bound)
by Gerd Schraner. I consider this the best refernence on wheel buildingā¦