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When to replace cracked rim?

6033 Views 25 Replies 16 Participants Last post by  GKSki
I noticed some very hair line cracks near the spoke holes of my 2001 rolf sestriere rear rim. The wheel still stays in true pretty well and is pretty solid. I suppose this is just a sign of age, low spoke count and high tension necessitated all the more by low spoke count. Trek told me that they don't have any more sestriere rims but I think the bontrager race lite rim is basically the same thing so I could probably rebuild it with that.

My question is how quickly do you think that I should replace the rim? I bet I could ride on this wheel for a long time still but I'm sure that if I mess around with trying to true it, especially in the areas where the cracks already exist, that will just hasten the demise of the rim.
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It's your skin

The question is how much of a gambling man are you? Me, as soon as I discovered cracks on one of my rims I'd stop riding on it.
Watching and waiting

ridewt said:
I noticed some very hair line cracks near the spoke holes of my 2001 rolf sestriere rear rim. The wheel still stays in true pretty well and is pretty solid. I suppose this is just a sign of age, low spoke count and high tension necessitated all the more by low spoke count. Trek told me that they don't have any more sestriere rims but I think the bontrager race lite rim is basically the same thing so I could probably rebuild it with that.

My question is how quickly do you think that I should replace the rim? I bet I could ride on this wheel for a long time still but I'm sure that if I mess around with trying to true it, especially in the areas where the cracks already exist, that will just hasten the demise of the rim.
If you want to keep riding these, then you need to learn how fast the cracks are propagating. To do this, mark a few spokes with a marker and measure the associated cracks with a ruler. Wait a few days and measure the cracks again. If the cracks are growing quickly, then you should be shopping for new rims. If the cracks don't grow, then measure them once a week and see where things grow. I have seen spokes pull through with almost no warning, and I have ridden a few 100 miles on rims after I noticed the cracks start.
If the ERD's of the two rims are the same, it will work with the same spokes.
My opinion soon. Whenever i have noticed cracks in rims, soon to follow at a minimum is noise under pressure, out of true, then spokes pulling out. Those rims are not real heavy duty anyway. I had a set of the Sestriere's and did not have very good luck with them.
As soon as I notice it. You take a chance of the crack getting worse and next thing you know your wheel will be wobbling side to side and you will have to stop and release your brakes so you can make it home.

Bontrager might make a similar rim. Problem is finding the same color. If it's black, you might be in luck.
What better excuse to get a nice new set of wheels? Once aluminum is cracked, in my books, it's in the trash and not worth the risk. When it ultimately fails, it happens fast and hopefully the worst of your problems is that your brakes rub.

Mark
Replace them now, while the cracks are small enough that some sucker on EBay won't notice them......
Replace it.

Even if the cracks are just in the anodizing, they'll propagate down into the base metal and the rim will fail. This is also why silver rims are more durable than anodized ones. The anodizing is very brittle, so it cracks under the bending loads the rim is subjected to, and because the anodizing is so intimately bonded to the base metal, the cracks spread into the underlying aluminum.

Aluminum is not a "tough" metal. Once damaged, it's ability to resist propagation of that damage is very, very low. Those cracks will spread, and your rim will fail.

It's time for new hoops. Oh, and don't reuse spokes.

--Shannon
How good is your health insurance?
Do you have short term disability?
new spokes?

tube_ee said:
Even if the cracks are just in the anodizing, they'll propagate down into the base metal and the rim will fail. This is also why silver rims are more durable than anodized ones. The anodizing is very brittle, so it cracks under the bending loads the rim is subjected to, and because the anodizing is so intimately bonded to the base metal, the cracks spread into the underlying aluminum.

Aluminum is not a "tough" metal. Once damaged, it's ability to resist propagation of that damage is very, very low. Those cracks will spread, and your rim will fail.

It's time for new hoops. Oh, and don't reuse spokes.

--Shannon
I found a Bontrager rim that should work. I'm curious as to the "don't reuse spokes comment." I can understand that new spokes would be a good idea but the spokes on that wheel haven't seen a whole lot of miles. Is the issue that the are fatigued and will break sooner than new spokes?
If the erd's are the same, you can reuse spokes. Just don't remove the spokes from the hub. Keep them in the exact same position or you will have trouble with them.
Erd?

MR_GRUMPY said:
If the erd's are the same, you can reuse spokes. Just don't remove the spokes from the hub. Keep them in the exact same position or you will have trouble with them.
What is ERD - something rim diameter? I think the Bontrager rim is a copy of the rolf rim but with Bontrager stickers. From what I remember, Rolf lost his rights to that wheel design and Trek assigned it to Bontrager. I think it's basically the same rim.
ridewt said:
What is ERD - something rim diameter?
ERD - Effective Rim Diameter. It is the measurement of the diameter where the ends of the spokes will be. In other words, two rims with the same ERDs will use the exact same spoke lengths (assuming the same hub and lacing pattern).

I think the Bontrager rim is a copy of the rolf rim but with Bontrager stickers. From what I remember, Rolf lost his rights to that wheel design and Trek assigned it to Bontrager. I think it's basically the same rim.
Well, Rolf Dietrich didn't lose the rights to that wheel design (the same basic design is currently be used by his new company, Rolf Prima). But Trek decided not to renew their license with Deitrich to use the "Rolf" name on their wheels. Trek still licenses the design from Rolf Detriech (although they really shouldn't have to, since the patent should be invalidated by prior art).

In any case, Bontrager rims all have their ERDs printed on their labels, and you can measure the ERD on your rim once you have the wheel apart, so you should be able to verify if the Bontrager rim will work.
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ridewt said:
I found a Bontrager rim that should work. I'm curious as to the "don't reuse spokes comment." I can understand that new spokes would be a good idea but the spokes on that wheel haven't seen a whole lot of miles. Is the issue that the are fatigued and will break sooner than new spokes?
Unless you stuff something into the wheel, spokes fail from fatigue. Each time a spoke passes through the load zone (at the bottom... the rim stands on its spokes), the spoke gets a little bit shorter, carrying the load by a reduction in tension. Wires (spokes) are very strong in tension and very weak in compression. You can bend a spoke in half by pushing in on the ends, but you can't pull one apart by pulling on the ends.

So each spoke in the wheel has one fatigue cycle per revolution. Yes, old spokes are more likely to break than new ones.

Also, when the spokes are detensioned, moved onto a new rim, and retensioned, each spoke's J-bend and hub end will have to come into cozy alignment with the hub again. This is essentially a permanent deformation process, and one that's unlikely to happen exactly the same way twice, so now you've deformed the spoke twice, and right where they always break anyway. Wires tend not to like that.

Will it work? Assuming the same rim, yes, it will. Will spoke life be affected? Yeah, it probably will. And spokes are cheap, and no fun at all to replace on the road. Especially drive-side rears, which are the ones that always break. Usually in the rain, alongside a 4-lane arterial highway with blind, cell-phone talking cagers blasting by at 75 mph with their headlights off, while eating a Double-Double and reading the Wall St. Journal.

If money's really tight, re-use the spokes, but if you've got the bread, buy new ones. The shop I worked at sold 14g DTs for $0.50 / ea, including brass nipples. Reusing nipples isn't the greatest idea, either.

--Shannon
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If two rims have different ERD's, they will need different spokes. If they are the same ERD, you can replace one rim with another without any trouble. Sometimes this is important on "fancy" wheels. For example, I was using a Mavic Cosmos rear wheel as a "fast training" wheel. After I crunched it, I was just going to replace the rim with a 28 hole Open Pro. After I did some digging, I discovered that the Open Pro had the same ERD as a Sun M-19 tubular rim. Using the same straight pull bladed spokes, the wheel was converted from a training wheel to a "race wheel".
Bizarro world

tube_ee said:
Each time a spoke passes through the load zone (at the bottom... the rim stands on its spokes), the spoke gets a little bit shorter, carrying the load by a reduction in tension.
Just curious, but can you explain to me why people insist on using this bizarre frame of reference? If the spokes go slack at the bottom of the wheel, is the rim still standing on the spokes? Of course not. The hub (and the weight of the rider) is being supported because the spokes at the bottom are reduced in tension and the spokes at the top are increased in tension. This does not mean FOR ONE SECOND that the rim is "standing" on the spokes. This reminds me of people who want to say that spokes are under compression because their tension is less than it was before. Theoretically true, but engineering sophistry at its apex.
Kerry Irons said:
Just curious, but can you explain to me why people insist on using this bizarre frame of reference? If the spokes go slack at the bottom of the wheel, is the rim still standing on the spokes? Of course not. The hub (and the weight of the rider) is being supported because the spokes at the bottom are reduced in tension and the spokes at the top are increased in tension. This does not mean FOR ONE SECOND that the rim is "standing" on the spokes. This reminds me of people who want to say that spokes are under compression because their tension is less than it was before. Theoretically true, but engineering sophistry at its apex.
It's a Jobst Brandt reference... Prior to his studies back in the early 1980's, prevailing wisdom was that the hub "hung" from the top of the wheel, and loads were experienced there. In other words, that the load zone was 180 degrees from the point of contact. The chapter in "The Bicycle Wheel" that describes how tensioned spoked wheels deal with loads is called "The Wheel Stands On Its Spokes." That's where the phrase comes from, so far as I know.

In reality of course, you are correct. If a wheel with 1000 pounds (tension) of spoke preload experiences a load of 100 pounds, then the effective load on the peak-load-bearing spoke is 1000 - 100 = 900 pounds (tension). If the loaded spokes were to actually experience a compression load, the wheel would fail immediately. Think Spinergy Rev-X left in the car on a hot day. Whether the upper spokes experience an equal increase in tension or not, I don't remember. I think they do, but don't have access to data.

I think also that the relative spoke/hub movement and bending that leads to fatigue failure is experienced more by the lower spokes, since the upper ones, having their tension increased, should be more firmly held in place, while the lower ones are less so. In theory, bending forces would be equal, just in opposite directions, but movement would be more on the lower side. Again, I have not data, this is a SWAG.

--Shannon
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Standing on the spokes

Kerry Irons said:
Just curious, but can you explain to me why people insist on using this bizarre frame of reference? If the spokes go slack at the bottom of the wheel, is the rim still standing on the spokes? Of course not. The hub (and the weight of the rider) is being supported because the spokes at the bottom are reduced in tension and the spokes at the top are increased in tension.
Not quite. The spokes at the bottom do reduce their tension, but there is no meaningful change in tension in the spokes on the top. Because the rim is radially very flexible (compared to the spokes), the rim easily flexes inward at the bottom of the wheel, allowing the bottom spokes to be de-tensioned, but transferring virtually none of the load to the top of the wheel.

You use the term "frame of reference", which is key to the "standing on the spokes" description. External loads are transferred through a structure by changes in forces/torques on the members in the structure. In the case of the bicycle wheel, only the spokes at the bottom of the wheel change forces, so they can be said to be the members that transfer the (external) load from the rim to hub. The static tension on the spokes is just that - static. An outside observer can not tell how much static tension the spokes are under just by looking at the wheel. But the observer can tell how the forces on the spokes/rim change when under external load by observing the displacements (flex) of the spokes and rim. From the frame of reference of the outside observer, the wheel appears to be "standing" on the bottom spokes.

The above may seem to be symmantic. But in another sense, it is very real. A wheel only works properly under load if all the spokes maintain at least some tension (i.e. the wheel looses rigidity if any of the spokes becomes slack). Since lower spokes can lose a large amount of tension when under load, the wheel relys greatly on the bottom spokes and their static tension. So in that way, the integrity of the wheel "stands" on the bottom spokes.
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BlueMasi1 said:
The question is how much of a gambling man are you? Me, as soon as I discovered cracks on one of my rims I'd stop riding on it.
Ditto- no such thing as an "ok" crack. It's done!

If it makes you feel any better, I just sent an otherwise perfect Zipp 303 tubular front wheel back to Zipp for crash replacement over a 1cm crack which extended perpendicular from where the tire seats through the rim braking surface. Wasn't a big crack at all, but is the beginning of the end. I didn't want to be worrying about my front wheel catastrophically failing on a 40mph downhill. As an added bonus, my wife insisted I get a new wheel so no additional selling to do there!
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