La Vie Velominatus: Building Wheels

Self-awareness is a non-optional ingredient of leading a fulfilling life; while we should always push ourselves to explore new things, we should also be aware of our limitations and weigh expectations against them. This is why I avoid any activities involving intelligence or a blow torch, and take particular care to avoid those involving an intersection of the two.

Learning to work on our machines is a path any Pedalwan must learn to walk, starting with simple tasks – perhaps to tune a derailleur or brake – and progressing gradually to building the bike up from a bare frame, seeking out a Cycling Sensei wherever new skills required suggest the need of one. A bicycle is a paradox; though it is a simple machine where one can plainly see the workings of most components, it is nevertheless deceptively difficult to maintain properly. Cables and chains are things of tension and their proper adjustment requires a delicate touch.

Bicycle maintenance today is easier than it was in the past as some tasks that used to take care and skill – such as adjusting bearings in a bottom bracket or hub – have all but been eradicated from the skills needed to maintain a bicycle as loose balls, cones, and races have been replaced by sealed cartridge bearings that are pressed into place and secured with a bolt. Adjusting these old bits required a mechanical sensibility that one seems either born with or without and is not easily taught to those who lack them; adjusting modern bearings requires little more subtlety than setting the dial on a torque wrench.

Wheel truing and building is a skill that goes back to the origins of Cycling and one which continues to live on, at least for the time being. Wheels are a marvel of engineering, one made more miraculous when, like me, you don’t really understand how they work: thin, flexible spokes leave the hub at various angles, some leading and some trailing the rotational direction as they either push or pull the wheel as we force it around using a system of chain, gears, and pulleys optimistically attached to our feet.

The wheel is kept straight and round by a delicate balance as spokes are matched in opposite pairs and tensioned to distribute forces not only laterally, but also vertically. Furthermore, spokes really only have strength in tension; on compression, they fold like a Schleck in a time trial. A well-built wheel depends on a precise balance of 3-dimensionally opposing forces in tension; should the builder fail to take this into account and a critical mass of spokes fail to do the single task assigned to them, I imagine the rider will explore a sharp learning curve as they discover the subtleties of riding a bicycle which goes abruptly from two to one or zero functioning wheels.

I have no delusions of being particularly gifted in a mechanical sense. When I was a kid, my dad called me “Threads” due to my penchant for over-tightening the nuts and bolts on his cherished Campagnolo components, leaving the poor dears stripped and useless. On the plus side, I learned how to operate a tap and die. But I somehow have never been terrible at truing and building wheels; whether its my methodical approach to tasks or my love for symmetry and balance that rescue me from myself when wielding a spoke wrench, the wheels I touch leave the stand true and round – and tend to stay that way.

Wheel building is perhaps the most pure form of the art of bicycle maintenance, apart from actually building the frame yourself; it had been a long time since I’d built a wheel, so I took it upon myself to build my own set for Keepers Tour: Cobbled Classics 2012. In keeping with my appreciation of my own shortcomings, I knew I was going to need a Sensei, and there was none better to turn to than our own Oli who happens to be a world-class wheel builder. Oli unhesitatingly and generously offered answers to my many questions as I collected the parts I would need, and even went so far as to study photographs I sent him when things went awry. That, together with the wealth of information that seems to flow freely on these pages, safely led me through the process, although there were some bumps along the way, assuming you consider needing to build the rear wheel twice and front thrice to be a “bump”.

Iteration 1:

The first round saw a flawless execution apart from one significant fact: when determining on which side of the rim the spoke holes are drilled, it matters which way you’ve got the wheel oriented, and whether you’re looking up at the wheel or down at it. Keeper Jim’s two-year-old son consistently demonstrates that he understands this fact, but still it somehow escaped me.

Iteration 2: 

I cleverly determined that I could just move all spokes one hole down and correct the problem from Iteration 1. I performed this task on both wheels before realizing I’d gone the wrong way and buggered the whole thing to the point where sending a photo to Oli resulted in the following remark:

Yes, something has gone wrong. There’s no way that you should end up with that situation no matter what rim or instructions you have.

Right, then. Moving on.

Iteration 3:

Rather than go back round and move the spokes a further two holes the other way, I decided to disassemble the wheels and start over. This didn’t bother me in the least because, as it turns out, building wheels is quite a lot of fun. You start with a pile of floppy spokes and dismembered rim and hub, go through a phase where spokes are poking out every which way, to a moment when suddenly it looks like a wheel and you feel like a genius (until you look more closely and discover you’ve balled the whole thing up). Each time through, I started with the front wheel as it is slightly less complicated owing to the fact that it uses all the same length spokes.

Experienced wheel-builders orient the rim such that the labels are readable when viewed from the right side; not wanting to upset any critical eyes, I naturally took care to follow suit. I also carefully oriented the front hub so that the “R” (Royce’s emblem) was oriented such that it, too, was readable from the right side (in addition to being visible through the valve hole).

Moving on to the rear wheel, I noticed that for some reason, Royce has the “R” inverted so it’s readable from the left side. I let out a slow sigh of resignation as I realized there was no way to avoid rebuilding the front wheel (again) such that the “R” on both hubs faced the same way.

The next day I tensioned the spokes and now the wheels sit in the basement awaiting a pair of tubulars so I can set about mounting them and start riding to ensure that any further lapses in my wheel building skills are discovered now, and not as we enter the Trouée d’Arenberg in April.

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234 Replies to “La Vie Velominatus: Building Wheels”

  1. @ Nate

    Thanks for that info.Very interesting.I wish I knew more about the production process.These rims are very very strong and that’s for sure.

    @ Minion

    Thanks!
    Sorry my man but I don’t know more about those stamped numbers.Almost every rim I saw has that B/86 no mater what year so no clue.I think only someone from production plant would know.

    @ Frank

    I don’t mean that your eyelets have discolouration..These are brand new rims and look gorgeous.I mean that overtime after some use and abuse over some stones,potholes,riding in the rain etc. discolouration begin to slowly appear on regular eyelets.Stainless eyelets don’t follow this pattern.I don’t have access now to my old wheelsets to take some HR close up photos of the eyelets to show the clear difference.Despite the discolouration issue the rims remain very strong.

  2. @frank

    From my experience with tubs Frank I’d advise you not to use the tape.Never.
    Has Rouleur referred to using tape as in Belgian Method for cyclocross or the tape as adhesive like Tufo Extreme without any glue?

  3. Cool post. Wheel building is an art. One I never learned, despite that fact I worked in bike shop for a few years. I am lame. At the time, other shop rats did the wheel building. I have however, trued a few zillion wheels.

    Wheel building is only piece of the bike puzzle I’ve never attempted. I gotta learn someday…

  4. @frank
    I have Folsom on vinyl somewhere. Today is the anniversary of the performances.

    Turntable is presently in storage — little boys in my house are hell on tone arms and needles.

  5. @TommyTubolare

    @frank
    From my experience with tubs Frank I’d advise you not to use the tape.Never.
    Has Rouleur referred to using tape as in Belgian Method for cyclocross or the tape as adhesive like Tufo Extreme without any glue?

    It was the Tufo Extreme, seems awful simple, and we used it to good effect on my dad’s HED’s, though it did seem the tires were tempted to come off. Having just done the first coat on my wheels and tires (a set of trainer tires), the glue way is definitely slower! But infinitely more intimate. Having a blast so far.

  6. @TommyTubolare

    Sorry my man but I don’t know more about those stamped numbers.Almost every rim I saw has that B/86 no mater what year so no clue.I think only someone from production plant would know.

    Mine do too.

    I don’t mean that your eyelets have discolouration..These are brand new rims and look gorgeous.I mean that overtime after some use and abuse over some stones,potholes,riding in the rain etc. discolouration begin to slowly appear on regular eyelets.Stainless eyelets don’t follow this pattern.I don’t have access now to my old wheelsets to take some HR close up photos of the eyelets to show the clear difference.Despite the discolouration issue the rims remain very strong.

    Right-o. Understood that’s what you’re saying – I’m pretty sure mine are stainless, but I’ll confirm in a few years.

    @Dan O

    Cool post. Wheel building is an art. One I never learned, despite that fact I worked in bike shop for a few years. I am lame. At the time, other shop rats did the wheel building. I have however, trued a few zillion wheels.
    Wheel building is only piece of the bike puzzle I’ve never attempted. I gotta learn someday…

    Go for it – its an amazingly fun project. I’m also dying to build a frame some day…I’ll do it some day, I’m sure, but for now, this is as close to building a bike from scratch as I’ll be able to get.

    @Nate

    @frank
    I have Folsom on vinyl somewhere. Today is the anniversary of the performances.
    Turntable is presently in storage “” little boys in my house are hell on tone arms and needles.

    Wow, big day!

  7. @frank

    @TommyTubolare

    Sorry my man but I don’t know more about those stamped numbers.Almost every rim I saw has that B/86 no mater what year so no clue.I think only someone from production plant would know.

    Mine do too.

    I think that might be a reference to a patent.

  8. @frank
    You’ll know why taking your time is good when you ride them and trust them to stick. Your Zipps are tubs or clinchers?
    I’ve found the grip and braking on tubs is nearly night and day over clinchers. Other factors meh, but if you can trust your glue its f’awesome.

  9. @Nate

    @frank

    @TommyTubolare

    Sorry my man but I don’t know more about those stamped numbers.Almost every rim I saw has that B/86 no mater what year so no clue.I think only someone from production plant would know.

    Mine do too.

    I think that might be a reference to a patent.

    Patent is ‘Brevetto’ in Italian so this seems a logical assumption.

  10. @Steampunk
    the thing is to ride the pave, having those treads would be something else. I live in London near Whitechapel, the killing ground of Jack the Ripper, so there are plenty of cobbled roads to ride hard and fast on. When dry they shake the colour out of your eyes, when wet they shake the colour and the shit out of you. It’s unnerving yet exhilarating at the same time.

  11. @marcus

    @Steampunk

    @frank

    @Spearfish

    @Chris

    @SpearfishThetford eh? I see from your profile your in Cambridge. I’m just up on the other side of Huntingdon. Who do you race with?

    The team name is MTFU, a slight regional variation on the theme of Rule #5.

    Mop The Fuck Up? A team of hardcore house cleaners? Awesome. Focused on the college crowd focusing on cleaning up after good parties?

    This is Britain, yeah? Surely: Mod

    nah -its what I say to my kids when the argue – Make the Fuck Up

    Ha ha! All good suggestions, mopping is certainly involved when you ride MTB in the UK winter. As for “mod”, I was always more of a rocker (was delighted to see Frank reference Pearl Jam a couple of days ago, Ten and Vs are two of my favourite all time albums) and “make the fuck up” has uses… 24 hour team racing can certainly have it’s moments!
    We came up with marinade the fuck up, to get drunk the night before a summer ride, then ride in your winter kit.

  12. @Chris

    @Spearfish
    I haven’t done any winter racing in the past. Those are mtb races I think, most of my mtb career was gravity based. Now that I’m not afraid of pedalling, I should get back over to Thetford.
    I’m planning on doing some road racing this summer though, Rockingham and Milton Keynes seem to be the ones round here. There’s also a crit in Spalding but thats the weekend after I disappear to the Keepers Tour which might be a bit hard to justify given that I’m warming up for the Tour with a Century sportive, the Cheshire Cat.

    Sounds like a good summer! I’ve been looking to get a few big sportives booked in around the MTB stuff, so I might well check out the Cheshire Cat. Not sure i’ve got my peleton technique sorted well enough for proper road racing yet though.
    You should definitely get out to Thetford when you get the chance, not much downhill but singletrack for miles and a really friendly racing scene.

  13. @zalamanda
    We don’t have any cobbles around here (Hamilton, Ontario) for better or for worse, but this time of year, the discolouration occurs on descents and trying to determine whether the dark patch on the road is wet or ice. Got most of them right this morning, but also had a couple of sphincter-clenching moments in a couple of turns…

  14. @frank
    May I ask what tires did you glue on HED wheels?Did you try to take them off yet after a puncture?
    I’d always avoid using tape and riding next to people who did use it.Although manual doesn’t say so it look like Tufo tape works best with Tufo tires as they have completely different liner and use butyl inner tubes.They behave and ride completely different.
    Tape sticks amazingly strong to a properly clean rim however never that strong to a tubular.You can easily wiggle the tubular with your thumbs what to me always indicates poor adhesion.
    Another problem that tape presents you with is changing to a new tubular after puncture. Removing the tape to mount a new tubie is a pain in the ass task.Tape leaves a horrible residue on the rims which is very hard to remove but have to be removed if you wanna switch back to traditional glue method.

  15. Had a blast gluing my tubs on; my bike looks very different with the Amrosios than it does with the Zipps…

    [dmalbum: path=”/velominati.com/wp-content/uploads/readers/frank/2012.01.15.02.45.26/”/]

    @TommyTubolare
    My dad had just gotten the wheels and we stuck some Conti’s (don’t remember which model) to them…they did seem very easy to move, though I don’t remember checking again after we finished our ride a few hours later. What was nice was the immediacy of the tape, as compared to my two-day journey with glue.

    But the glue was amazingly ritualistic and fun, and I wouldn’t trade it for the world. And the tires seem absolutely bolted in place. Based even on how hard it is to pull the tape off, it seems like more of a hassle than it might be worth. Plus, I have an enormous tub of glue to use up before I consider making the change!

  16. The tape scares me to death! The time spent applying layers of glue to rims and tires gives me confidence that my tubs will stay in place in a turn at 75kph. The tape seems (although it may just be technical progress) like a too good to be true shortcut that will end with me face down off the side of the road… Did I mention it scares me to death?

  17. What was the name of Sean Kelly’s domestique – Rudy something – remember watching him lose a TDF stage rolling a tub coming into the last couple of corners. Always put me off the tape, as well as making me grateful I wasn’t his mechanic.

    I had one happen to me at the weekend doing the Round the Mountain – hit a pothole when I got a bit tired towards the end and the nipple itself sheared in half. Pulled the spoke out, opened out the QR and carried on with no worries – but that’s a new kind of breakage on me…

  18. @frank
    Holy crap. I’m really starting to wonder about my life choices: I’d happily live under a bridge in rags with one of those wheel truing devices. That thing is beuuuutifuuulll. Of course I’d be hungry, alone and delusional but it’s be worth it.

    @TommyTubolare

    Cheers, thanks for all the info. BTW I tend to concur with your opinion on tape (unless you’re a triathlete) because it seems to be a solution on search of a problem, which doesn’t clearly provide a better solution.

  19. @Minion

    Cheers, thanks for all the info. BTW I tend to concur with your opinion on tape (unless you’re a triathlete) because it seems to be a solution on search of a problem, which doesn’t clearly provide a better solution.

    RIght, so tape is like disc brakes on a road bike.

  20. @Simon

    What was the name of Sean Kelly’s domestique – Rudy something – remember watching him lose a TDF stage rolling a tub coming into the last couple of corners. Always put me off the tape, as well as making me grateful I wasn’t his mechanic.

    Rudy Dhaenens. I didn’t realise he’d died, or what an impressive palmares he had. Sorry for calling him Kelly’s Domestique…

  21. @frank

    Sent to me by windsurfing legend and badass cyclist, David Ezzy

    if you had been sent a love letter from the Queen of England, I would have been less impressed – in my former world Dave Ezzy was God – I had a full quiver of his wave sails (actually, still have them if anyone wants to buy a set – look great hanging on a cafe wall…) – anyway, I’m seriously jealous of that man love

    doesn’t surprise me he is a badass cyclist, as he was a fuckin nutter on a waveboard – one of the great pioneers of big wave sailing in the later early days – sadly before video cameras could be taken into the surf for youtube benficiaries – major inspiro

  22. I use 3M Fast Tack for gluing. One bead right out of the tube one the tire then spread with a finger and one one the rim straight down the middle over the nipple holes (starting at the valve hole and finishing there). Then the tire goes on and if the right amount was used only tiny little bits squeeze out. Its ready to ride in a few hours, bullet proof and has a good residue for mounting old tires when you get a flat. The whole thing takes about 15 minutes…

  23. @Rob
    The problem I’ve had with Fast Tack is of it eating through and separating the base tape from the tire. But its availability in nearly every auto parts store around the US and ease of use you point out certainly saved me from riding the training clinchers on many a summer racing road trips.

  24. @Simon
    It was Rudy Dhaenens, but he made up for it by becoming an undeserved World Champion the next year! He was off the front in the 1989 Tour and rolled his tire. But as @Oli says, I’ve never heard he was on tape? I’d heard he was just on a poorly glued tire.

    I’ve tried many, many times to find that video…

  25. @Dr C

    @frank

    Sent to me by windsurfing legend and badass cyclist, David Ezzy

    if you had been sent a love letter from the Queen of England, I would have been less impressed – in my former world Dave Ezzy was God – I had a full quiver of his wave sails (actually, still have them if anyone wants to buy a set – look great hanging on a cafe wall…) – anyway, I’m seriously jealous of that man love
    doesn’t surprise me he is a badass cyclist, as he was a fuckin nutter on a waveboard – one of the great pioneers of big wave sailing in the later early days – sadly before video cameras could be taken into the surf for youtube benficiaries – major inspiro

    Yeah – his son is a fucking badass as well. Only bloke in the world who can do a no-handed backflip on a windsurfer.

    I spent an afternoon drinking seawater with David last summer. Top notch guy, and the origin of Rule #86 after he casually tossed me in the hurt locker on a spectacular ride to Kaupo on Maui.

    Frank: So much for a casual ride today!
    David: I’m not the one setting this pace, you are!
    Frank: I’m just following you!

  26. @Rob, @jimmy
    How long does it take to eat through the base tape? And, I’m assuming, this would cause an issue in terms of the tire coming straight off the rm?

    Is the rate it eats through relevant to the life of the tire? Seems a very easy and quick way to glue a tire!

  27. Late to the party, been off for a while.

    I am lacing a set of NOS F20s to a set of C4 hubs right now. I will post some pics from the laptop

    @frank Welcome to wheelbuilding! May you never go back to factory again…

  28. @jimmy
    @frank
    I hear you on the base tape but it never seemed to be an issue for me. A few times I would re latex and or just re-glue base tapes but usually I would have gone through a tire. Maybe once and a while (all this would also depend on the quality of the tire) the base tape would separated when you were changing tires because the Fast Tack is so strong. I never had any problems on the road and absolutely trusted the stuff. And yes, once you get the technique it is a very good and fast method.

  29. I wouldn’t mind to use Fast Tack if the carpet in my living room come loose but never on my tubs.
    Fast Tack fast drying properties cause base tape split and separation from the rest of the tire risking rolling off the tire in a moment you’d at least expect it.Since I usually try to repair my tubs using old needle and thread method I want my base tape in the best condition it can possibly be after a puncture.Plus Fast Tack dries too fast so if you are new to gluing tubs and you happen to make a fault it’s harder to align the tire properly.
    Use it if it works for you but I’m as fast with normal glue method.Since I already have a glue on a rim from previous gluing all I need is a bit of acetone to reactivate it and one thin layer on a rim plus one thin layer on a new tubie.That’s it.
    The only time Fast Tack is quicker is when you get a new tubular wheelset and have to go through your initial glue layers.

  30. @Rob
    The 2nd glue job was when I’d see the deterioration. The base tape would peal away and curl. Track wheels, CCX wheels, where the tire could live longer than the glue was what got me off the 3M. But as Rob described, the ease of use and quick drying made good use for the road wheels where the rubber would be used up by the end of the season anyhow.

  31. @ Minion

    Thanks mate.No problem.And yes tape is a solution to the problem that never really existed in the first place.

  32. @frank
    Um, pretty much? The bond you get from properly glued cured tubs is really impressive, and when you corner and brake, well it’s kinda hard to explain. The point of multiple layers is to soak the base tape, and turn that whole thing into an adhesive tape. Tape seems much more superficial in terms of the available bond, and while it might be fine with modern tubs (wrapped one piece construction rather than sewn up traditional tubs – see Conti and Tufo) and for triathletes (go in a straight line on the flat and brake twice if you’re doing it right) if you want a more reliable bond, for more varied use, (cornering, descents, frequent braking) I want the best bond available. (talking out my arse discalimer goes Here).

    Of course the greatest force holding the tub inplace is the air in the tire. But we don’t talk about that when arguing the merits of different methods.

  33. @minion
    I’ve used the same type glue for road, track wheels (120+ psi) and cyclocross (30-50 psi) wheels. Have not had a problem with adhesion for either. I’ve never tried the tape or tape+glue methods. I figure a rolled tire is caused by A) impatience of not administering glue properly or B) not checking the condition of an old glue job or someone else’s work (of which I have been guilty of to the tune of a broken scapula).

  34. @TommyTubolare

    @jimmy
    Both of you are spot on, good points, my use was strictly road and I never had tires that went more than 1/3rd of a season.

    I have to throw in here to anyone new to glue jobs – please do not mix glues/techniques stick to one method at a time and start fresh if you change to a new method. Like Jimmy the only time I ever rolled a tire was when my bike shop mate did me a favor and glued on tires for me using a different glue – soon after my chin became intimately familiar with an switch back in Puerto Rico. Really my fault because I should have had the brains to ask him what he used.

  35. Nice article Frank. When you build up your own bike and do your maintenance it forges a bond between man and machine like no other. As a kid I learned how to work on bikes out of necessity, now I do it for the love of my machine and sport. Surely the Gods of The Arenberg will show you the path of least resistance as you ply your way through cobbles.

  36. @El Mateo

    Nice article Frank. When you build up your own bike and do your maintenance it forges a bond between man and machine like no other. As a kid I learned how to work on bikes out of necessity, now I do it for the love of my machine and sport. Surely the Gods of The Arenberg will show you the path of least resistance as you ply your way through cobbles.

    Beautifully said, and thanks!

  37. Currently bidding on a pair of Nemesis wheels. Seller doesn’t have a clue what they are because there is no info about the hubs or anything. Bidding is at £1.04 with a day left.

  38. @minion
    It’s a good thing ebay bidding is anonymous!

    @lucky
    They’re collect from seller only. Do you live nearby, if so could you pick them up for me and pop them in the post? Ta.

  39. @TommyTubolare
    One wheel completely cleaned. Man what a bugger of a job! Took around four hours to get all the old cement off, even with acetone. But now it looks like it is straight out of the shop.

    Put the 27 on it to stretch overnight and will glue it tomorrow, hopefully. I have my first licensed road race tomorrow morning since the early 90’s so no idea what shape I will be in tomorrow after the race!

  40. First day on the tubbies! One ride isn’t enough to go off, but I think I might be a convert. Nothing at all wrong with riding clinchers, of course; they are very good tires. But there is something intangible, something more solid and firm about riding tubulars. Very good ride and loads of fun in any case.

    (These are the training tubbies, not the FMBs…)

  41. Always in awe of that saddle-bar drop.

    Did you glue them on or use Tufo tape? Seems the tape would eliminate the negative aspect of trying to change a tub if you puncture, i.e. messing about with the glue.

  42. @Buck Rogers
    That’s cool man!
    Cyclocross riders really use a lot of glue.Their one thin coat is like my wheels after third! I understand they run tubes on low pressure however most of the times the amount of glue they use it’s an overkill.That’s why it took you so long.

    I’m glad you took the time to do it and do the same when gluing.Remember that once you’ve done the initial glue coats yourself you do not remove the glue completely again when mounting new tube so all hard work now will pay off later and gluing a new tire will be a much quicker process.

  43. @frank
    Nice one Frank!
    Really like the way your bike looks with those wheels.Nothing wrong with Zipp 404 but this look it’s just different.
    By the way do not try to test ride 404’s in tubular version cause you gonna have a big fucking dilemma.Better forget that I even said it.

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