Help finding spokes for crystalyte HS3540 rear motor

moostrodamus said:

Hey everybody,

I smacked a big pothole and broke some spokes on my crystalyte hs 3540 Rear motor. I live in Toronto, does anyone have a set of twelve gauge spokes for this motor i could buy, or does someone maybe know a good source for these?

Many thanks for your input.

Moo

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moostrodamus said:

thats great!...would John what i was talking about if asked for a set of spokes for a rear HS3540, or would i need to specify the lenght?

Which i dont know...

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Philistine said:

ebikes.ca have a spoke calculator as well, you punch in the motor type and the ERD and it gives you the spoke length. I used the calculator for a HS3545 and a Mavic Rim I didn't even have yet (just using the ERD from the website) and used the Ebikes calculator, and sent John that length, and it calculated perfectly.

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richmpdx said:

If you are going to replace spokes, it is really a good idea to measure a spoke from the wheel. I had several spokes break in an HS3540 in a 20" wheel. I used the table on ebikes.ca to look up the spoke length and ordered a bunch of 12 gauge spokes based on the values in the table. They were too long. So Crystalyte may use different rims at times, and therefore different spoke lengths required. After measuring spokes from the wheel, I got the correct replacements.

Another good place to get custom 12 gauge spokes is Ebikes SF. They have prepared and shipped spokes very quickly. Spokes are on this page:

http://ebikessf.com/catalog/41

Cal, spokes for the HT3525 should be the same as for the HS3550 as the dimensions of the hubmotor should be the same, just a different wind.

Rich

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moostrodamus said:

Here is the spoke size....I have someone who says they have a set...sent them this pic to see if its the right size...i dont know where you measure too or frum but this shows the whole thingy...

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I just hook them over a ruler, which is the way I have heard from all other bicycle mechanics. From the inside of the elbow on the head. This is also how the spokes come measured from Sapim. Hook them over a ruler and it is dead nuts what they are labeled. It doesn't make more than a mm difference, not enough to throw a build off unless the spokes are already way off.

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richmpdx said:

From a thread on sale of custom spokes by John Holmes:

I just hook them over a ruler, which is the way I have heard from all other bicycle mechanics. From the inside of the elbow on the head. This is also how the spokes come measured from Sapim. Hook them over a ruler and it is dead nuts what they are labeled. It doesn't make more than a mm difference, not enough to throw a build off unless the spokes are already way off.

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For more discussion of measuring spokes see the thread:

http://endless-sphere.com/forums/viewtopic.php?f=31&t=16218&start=255

It is a little hard to tell from the photo, as the ruler doesn't go from the inside of the elbow to the end. But it looks like that spoke is even shorter than the 77mm spokes that are OK for my HS3540 in a 20" wheel.

Cal, that Crystalyte document indicates it is dimensions for both the HS and HT Hubmotors, i.e. they have the same dimensions. Spokes that work for one should work for the other. That said, the spoke length listed for an HS3540 on the ebikes.ca site didn't work for my HS3540. As they say, YMMV.

Rich

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richmpdx said:

Cal,
To start with a disclaimer, my knowledge of wheel building is very sketchy, maybe somebody with more knowledge will respond to this thread. If the data you entered is correct, then the spoke length should be OK. About the data, how did you get the hub flange diameter? It is my understanding that this measurement is the distance between the center of one spoke hole to the center of another spoke hole on the opposite side of the same hub flange. That measurement isn't shown on the crystalyte pdf file you attached. The value given for this on the ebikes.ca site is 233 mm. I haven't tried to directly measure it on my HS3540. If you use 233 as on the ebikes.ca site rather than 228 that you used and an ERD of 536, 1 cross, you get 162.8 or so depending on which calculator you use. Of course that is about 2 mm shorter than the calculated value if you use a flange diameter of 228. I am not sure, but a 2 mm difference maybe relatively easily accommodated by a 1 cross pattern. For what it is worth, the Ebikes San Francisco website lists some spoke lengths for various builds with Crystalyte H series hubs. For a 1 cross pattern, ERD 544, they list 167 mm as the spoke length. If I use hub flange 233, ERD 544, 1 crosspattern in the UBI spoke calculator, I get the same value as the spoke length on the Ebikes SF site, 167 mm. So it is a very indirect confirmation that the 233 mm flange diameter can be used.

Please post the spoke length that works when you get it sorted out as I am interested in a new build and need to solve the same kind of issue.

Rich

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