As promised I have taken a few photos to show how I reclaim old demountable wheel spokes for reuse on the wheels requiring shorter spokes. I will used several posts because there are lots of photos.
First step is to collect all the spokes you can find and cull out the best. First I remove all the rejects... cracked, rotted, buggered up hub end. Then start selecting the best left over until you have 12 for each wheel.
When you look at the hub end not that one edge has a bevel which faces in close to the hub. Then each spoke has a 1/2 hole for the bole. You can consider each hole a right or left. Since we don't want to re-drill these holes you will need 6 rights and 6 lefts.
Next prepare and finish the spokes however you like... primer, paint, sealer, stain, varnish, left as-is... whatever. Now is the easiest time. It is also a good time to finish off your felloe and hub.
Here we have an old spoke (above) and an earlier spoke (below) ready to be reclaimed.
First mark the length of the spoke by comparing it to a known good spoke.
The mark should be subtle.
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Next set up your lathe with a 4 jaw chuck.
Insert spoke into chuck.
Set chuck so it doesn't ride on the bolt hole.
Center the spoke in the chuck end.
I use a drill chuck in the tailstock to hold the spoke steady. Set it lightly touching the existing tennon. A live cup shaped center would be better if you have one.
Set up your first cut on the mark.
First cut... leave MORE than 1/2" thickness.
Turn tennon to approximate size.
Check size... I'm going for a couple thou over 0.5".
Continue to creep up on the diameter you want.
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Remove spoke and check it out!
If you want round wheels check to be sure all spokes are exactly the same length.
Trim tennons.
Wheel ready for assembly.
(cont.)
Wheel assembled.
Any questions?
Respectfully submitted, TH
Does the press work OK with these shorter spokes?
Yes.TH
Very cool , thanks Terry.
I always look for re-purposing opportunities. Good job Terry !