Making Oversized Spokes
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- เผยแพร่เมื่อ 2 ส.ค. 2024
- This video shows an easy way to make spokes of virtually any length!
Here's a link to a video showing a thread rolling machine:
• Thread Spokes - Head T...
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This fellow is the Bob Ross of metal forming. I could see him saying things like "Now we will just make a happy little bend." or "there are no mistakes on only happy unplanned alterations to the pattern.".
Thanks!
"Bob Ross" works. When I first started watching Ron's videos, he kind of struck me as a Mr. Rogers for grownups. Gentle voice. Speaks slowly and clearly. Always smiling, but never in a way that's condescending or prideful. I'll probably never make a wheel but Ron's videos are so educational and entertaining that I watch them all. Twice.
Wow - thanks for the wonderful comment!
great video Ron! enjoyed.
Thanks so much, Tony. You posted a masterpiece this morning!
This Old Tony is the best too! It is awesome to see you watching other cool creators
Thanks for showing the mistakes and how to adapt. It’s nice to know even a master is always learning!
Always!
I love how Ron casually knows more than everyone about everything but isn't cocky or arrogant about it. He is just happy to show us mere mortals some of his tricks.
Well, thank you for the compliment - but I certainly DON'T know everything. I try to learn something new each day, and I love hanging around with people who are smarter (or more experienced) than I am.
Ron, I know it takes a little more time to convert the measurements that you do, to standard units, but know that this helps us viewers from outside the US, A LOT! I can't imagine how much "thousands" are, but I can understand those millimeters! Haha nice project! Your excellent craftsmanship really shows in every project!
Well, I grew up with the Imperial system, and it's the one I understand intuitively - but I realize that only 3 out of 193 countries use it, and I want my videos to be understandable to as many people as possible.
I have a question: is a "ten thirty two" screw twice as big as a "five thirty two" screw, and if not, why not?
😄
I certainly acknowledge that the Imperial system has some quirks. Threads 6.3mm and smaller are designated by a number, and larger threads are designated by a fraction. And no, a #5 screw is not half the diameter of a #10 screw. I can't tell you why this is the case, but I do understand why more rational systems are used by most of the world.
If you think the thread sizing system is odd, look into how the thickness of sheet materials are measured. The larger the gauge number, the thinner the material!
@@RonCovell It is great comfort to find that there are still North Americans who can respond in a sweetly reasonable way to a bit of light-hearted ribbing. You're not of Canadian extraction, perchance?
If you're a born and bred citizen of the US: Have you ever thought of standing for high office?
Well, I do consider myself a 'born and bred' US citizen, bur really, the vast majority of everyone in North America has ancestors that came from somewhere else. I have no interest in holding any political office. My life is complicated enough as it currently stands!
I love the way you teach. Not so slow as to bore the viewer and not so fast as to easily miss some detail. Of course given we are watching a video, it's possible to rewind and catch detail that was missed. However your rhythm seems to be just right. At least for me. It's a pleasure to look over your shoulder so to speak. I always find something new I hadn't thought of before.
Thank you so much, Ja'nette - I'm glad my style is a good fit for you. We are in a very fast-paced age, and my style is a bit slow for some people - but it's very nice to know that it works for you, and many others.
Ron, the first two years of my toolmaking apprenticeship was at the Ford Apprentice Training Center at Harrold Hill, Essex, UK. A storry did the rounds one day about the chief instructor was doing his rounds when he came across an apprentice holding a hammer half way along the handle. We'd been taught to always use the full length of the handle, so the chief instructor took the hammer and cut the excess handle off with a hacksaw, and returned it to the apprentice. I was reminded of that story seeing you hammer the spoke flare. I think I now own at least a dozen assorted hammers, and I am sure there are times when I don't use the full length of the handle.
Well, when you need maximum power, there is no question that gripping the handle near the base is the best strategy. But sometimes, a lighter hit is preferred, and that's when I 'choke up' on the handle. In my mind, it's not a 'one size fits all' thing.
Very cool.
This was my one question.
In answering it, you made me realize (yet again) how taking a little time with simple tools, making a jig or tool is the key to making almost anything.
Yes, simple fixtures can really expand your capabilities!
Time and expense invested in simple fixtures minimizes time wasted in frustration and mangled parts.
Also, a quality fixture can result in VERY repeatable tolerances for making a lot of things that are practically identical, such as these spokes.
I love that you showed the aluminium fixture first. You've probably saved that time to anyone trying to do this.
We all can learn from the mistakes of others.
ENJOYED…..simple craftsmanship tutorial from an expert….lots of subtle tips/lessons
Glad you enjoyed it!
Ron,
Thank you for sharing your expertise & knowledge with us. I too, appreciate , that you show your set backs as well as the finished products.
Rick
Glad you have learned from my missteps!
After watching awhile and learning so much I finally have a good tidbit of knowledge to share. The jig you used to make the heads is basically the same as what I use to make rivets. The key length to forming a good rivet head is one and half times the wire diameter.
That's a good tip. I think the formula would be a little different for a 'head' that has a taper, which fits into the countersunk recess in my fixture.
Watching a master is a wonderful thing! Good stuff Ron👍
Thanks 👍
Someone asked me to restore a penny farthing recently: Your videos have given me confidence in rebuilding the front wheel (i have the hub but nothing else). Thankyou.
That is awesome! Sounds like these videos came at the perfect time for you.
Nice one, first a Tony video then a Ron video, that's what makes my day.
Yes, it's a good weekend. I'm just about to watch the new Blondihacks video, too!
It's mint how you show the actual testing and modification process!!!!
Yes, that's an important part of many tasks.
I love your videos! Especially how much you show the fixtures, jigs, and clamping mechanisms that go into many of your hand-made parts. It really emphasizes how much effort has to go into custom fabricating the tooling before even starting on the part- if you want it to come out right!
Yes, I'm 'big' on fixtures. Even though they take time to make, they often allow you to do things that just wouldn't be possible otherwise.
Very cool! You are a good spokesman for metal working...
I'll get me coat
SPOKESMAN? - HAH - I get it!
Wow, that amount of work to get the detail you are after is amazing. Keep up the good work.
Thank you very much! More videos on the way.
Howdy again Ron. So glad you are showing we are not perfect, making dies, bucks etc, doing test pieces by trial & error is not only just the way to go for consistency & also accuracy. 😉
Yes, that's how work gets done in the real world!
Learn to fixture like Ron and it all downhill from there! Another great video! Thanks Ron!
Thanks for watching!
That's brilliant Ron, even though I've been around dirt bike and bicicles all my life and respoked many many wheels I never really thought about the process involved in maufacturing the spokes. It's pretty straigt forward really. Thanks again.
Of course you would buy spokes if they were available, but I needed some unusually long ones!
Always a pleasure to see a master at work.
I'm so glad you liked it!
How does Ron not have more followers? Amazing content for a brilliant man!
Metal fabrication is not for everyone, and I'm glad that 185,000 people have chosen to subscribe so far!
Beautiful work Ron. I build custom wheels for various contraptions and until now just bought the cheapest spokes that I could find (that happened to be longer) and then cut them - the garage is covered in 2mm offcuts! I’m absolutely making RC style spokes from here in. You can buy the rolling heads for those machines for around $30 make a little arbour for it from mild steel and run it in a cordless drill - works great once you get the pre-load in the rolling head dialled in.
Wow - that's great to know! I have always sent my spokes out to be threaded, since I thought thread rolling machines were super-exensive.
Ron, Tony and Aaron.. that's a nice weekend!
Yes, and don't forget Quinn at Blondihacks!
Fascinating. I'm not making metal parts, but now I know how it's done.
I'm glad you enjoy watching!
Thank you for sharing your wonderful gift Ron
My pleasure!
I've been having fun watching your channel. I had a friend a few decades back who had his own machine shop in his basement. I always got a kick out of watching him work and seeing how he would create parts for his customers. A pile of metal and bits on one side of the room and finished products on the other. It was fascinating. Thanks for bringing back some of my memories.
How great - I'm glad you are enjoying my videos!
You are now my favourite spokes person. ;)
HAH - good one!
I like that you show mistakes and then solutions, we learn by mistakes, it helps us think in ways that solve problems. (after I throw my screwdriver at the wall)..;)
Yes, we all make mistakes, and then have to re-calibrate.
Extra content:
How to gradually increases the value of the fixture until you hit the top of the "bell curve" of low cost versus effective enough.
Yet again my hat is off to the Master, You bet I am subscribed for more!
Glad you liked the video - more to come, for sure!
A fine example of the toolmaker's art. Well done, Ron.
Thanks so much!
Great video. show the failures so others can learn, like a teacher I had while restoring classics back in the 80s, same guy showed me classic car magazines with some of your work in, just 34 short years ago.
I'm glad to hear that. Man, that time went by in a flash!
I’m not a guy who comments much on TH-cam. You, sir, deserve a lot of praise and respect for sharing your meticulous work. You seem so happy with life and so much at home with metal working, it’s a joy to be part of your circle, thru this channel. Thank you, Mr. Covell. Thank you!
Wow, thank you!
Thank you for showing your mistakes. It's wonderful to see how your creative process works. A methodical and measured approach. Keep the videos coming!
You are so welcome, and there are more videos on the way!
Cool process Ron. Always love to see your jigs/forms and your thought process. Thank you for sharing your knowledge 👍👍
You are very welcome!
You got your homepage back! 🧡
Yes, Deena. A knowledgeable viewer showed me the steps!
Just love watching your process, your thoughts, ideas, actions and adaptations.
Thanks so much!
Muchas gracias por compartir su trabajo señor Covell...
Estoy tan contento de que te guste!
Nice to see someone continuing the lost art of tool and die making.
Yes, we can't let those skills die out!
@@RonCovell Ha, ha! You are such a tool!
I really appreciate that you showed building the first fixture, then troubleshooting why it didn’t work to expectations and then making a new one. And…I suddenly have an inexplicable desire to make a giant wheel and spokes!
Joe - you could make a quadricycle - loosely based on Henry Ford's early prototype, but with giant wheels!
This is my second video or yours friend. The first was the 55" diameter wheel that these spokes go into. Well done. From Asheville, Daxx
Thank you so much!
Thank you so much for sharing your knowledge, I truly appreciate all the efforts to share your craft, some ppl do not want to share their knowledge, I have gotten to the age where I feel the need to pass my knowledge, as well as learn, there is a lot I do not know, I love knowing how things are made, how they work, and making things has always been my thing! Thanks again! 👍😀
You are so welcome!
Glad you did not edit the first attempt in making the fixture, it is more realistic this way, I really enjoyed watching the process of getting the result you were after.
Glad you enjoyed it!
Thanks for sharing Ron! Glad to have another method to straighten wire. Rolling between boards is a pain and using a vice and drill seems to work harden the wire. I'm gonna give the car method a try!
Glad to help!
Thanks for sharing your skills with us! I really enjoyed following along with the process of just experimenting to see what works.
You are so welcome!
Nice work Ron and a great pleasure to watch. Please keep posting.
More to come!
Brilliant, you are a natural teacher sir. Thank you for sharing.
Many thanks!
Great video Ron, I always learn a few things watching you.
I appreciate that!
Awesome work Ron! Your fixture making is top notch!
Thanks a bunch!
Ron, I tried to follow all your instructions. But not having a car to stretch the wire was a problem. In the end, I tethered it to my wife. And told her there was a sale on in town. I think I need a stronger wire. Thanks for all you give.
You found a creative solution.
Thanks Ron ! Straight Ahead ✌😎
Amazing! I always learn something new watching your content!
Awesome, thank you!
As always, an absolute pleasure to watch, mistakes and all.
Thanks so much!
Great to see you again. I'm impressed by the car, I would never have thought of that.
Hey, thanks!
Nicely done, Ron.
I know you often do, but it was especially good to see you work through issues.
Thanks for posting,
Joe
Thanks, Joe - I'm glad you enjoyed it
I like that you included your first, failed attempt. You’re a great teacher.
Thank you so much!
Thanks for sharing this Ron! Exactly what I asked for.
Great!
Nicely done Ron, well made spoke.
Thank you, Randy. You certainly know your way around a shop, and I appreciate your comments!
The spoke threading and sometimes cutting machines are incredible tools. Some take only a second to accurately trim, then thread a spoke. One tool I couldn't justify purchase, relying on custom order of spoke lengths.
Yes, the tool I showed a picture of is a couple hundred dollars, but some cost thousands!
Great video Ron.
Glad you enjoyed it
Thanks Ron , always enjoy your videos. That is a huge wheel.
A couple of people have asked me to make a bigger one!
@@RonCovell that will be interesting. Can't wait to see it. Thanks
That straitening technique also work hardens the wire, I suspect it wouldn't be strong enough without that. great stuff
Yes, the wire is pretty soft when I get it, and the stretching does make it stiffer!
Love it. Made me think about the first bicycles of great grandparents and the value they had.
Yep - that's how they used to do it!
I always learn something from you Ron! Thanks
Thanks for watching!
Very interesting Ron! Thanks for the video!
Glad you enjoyed it!
great job as always mr covell
Thank you kindly
cool presentation Sir
Many many thanks!
I've worked with Stainless (mostly 316 & 305) turning & milling components. Most grades are actually fairly soft. However Aluminium is usually even softer & less far tolerant heat, so I'm not surprised that became an issue for you. You're quite correct about forming the threads. Using a die to cut them would probably lead to stress fractures. A rolled thread will be stronger & more robust in tension.
Have you considered using thicker spokes (such are used in Tandams & some other applications. These bigger wheels may benefit from using them.
Most high-wheeler replicas use larger diameter spokes, and that would be a good idea for a vehicle that gets a lot of use. Mine is for only very occasional use, but I appreciate your suggestions!
Thanks Ron, great video!
Glad you enjoyed it!
Great video as always Ron.
I appreciate that!
Good work Ron.
Thank you kindly!
This will come in handy when I'll need to rebuild the wheels for my Coker Monster Cruiser!
Cool machine!
Thanks Ron
Thank YOU for watching!
Excellent info. Now I have to try this!
Go for it!
Ron you sir are a legend !
Thanks for watching, and for commenting!
Thank you Ron!!
You're very welcome!
Excellent work 👏👌
Thanks a lot 😊
Nicely edited video
Thanks, I appreciate that! I put considerably more time into editing than shooting.
Thanks for making this. Awesome video
Glad you liked it!
@@RonCovell Been thinking about it. Your first attempt at a jig. Did you not just drill the bend radius hole in the wrong place. Should the radius of the drill hole size not co-inside with the desired internal bend of the wire. Therefore not resulting in that weird collapse and double bend you got when you tried riveting it over. that said, the second attempt work just as well
I think the solution you suggest here could work, also. Thanks for your thoughts.
Really liked the car trick ron
Yeah - not many people think of that.
thanks for the great videos
Thanks for watching!
I like the car Trick , I've used 2 Trees and a come along to straighten 3/16 Stainless Tubing.
I'm sure your cable ratchet technique worked well!
And hopefully your local bike shop has a sweet Phill Wood thread roller. Mechanical poetry.
Actually, Watsonville Cyclery DOES have a Phil Woods thread rolling machine - one of the earliest ones he produced. I have seen it in action, and it's an engineering marvel!
@@RonCovell It must be a two person job with spokes that long!
Pretty sharp, sir 👌 👍
Thank you kindly!
Super job! It appeared the aluminum fixture sucked the heat away quicker than the steel fixture did.
I know it looks that way. I don't have a good way to gauge it, but I would think the two metals would be about equal.
Bravo!
Thanks so much!
Your the Bob Ross of fabrication. Then I looked down in the comments and see I'm not the only one who thinks that. (ha ha) Excellent tutorial !
Yes, it's been said before, but I consider it a very big compliment, and I thank you.
I love this guy!
Thanks!
@@RonCovell I'll have to come and take one (or more) of your class.
Hope you can. I'm teaching one class a month these days.
Looking at this massive wheel (and my grandpa's old horse drawn carriages) I had an idea:
An electric driven horseless carriage fitted with those giant wheels. It's gonna be ridiculously expensive and probably not street legal, but someone gotta do it
I like your idea, and I'm nearly certain there is a legal way to do it!
Just keep the max speed under 25mph (demonstrated thru rpm/gearing/diameter) and it's just a funny-shaped golf cart or Neighborhood Electric Vehicle.
Great tip on stretching wire to straighten!
Also, watching that process, and thinking about doing it 72 times, had me wonder if there was any cam locking system or clamp that could have helped expedite the process over those two screws. Tedium terrifies me. 🤣
Yes, there are many types of locking clamps that could expedite the process Here's one example:
th-cam.com/video/WjboLU8vgug/w-d-xo.html
The Master
Very interesting
Glad you think so!
I live anything bicycle related and this is right up my alley.... I've always wanted to make a bike from scratch and literally make everything but I know my welding experience is lacking so I'd need some practice before I go trying to make one, but this is very useful information. Thank you and keep up the great work... 😁
The first bicycle frame I built was a lugged design, and I silver soldered it together. The learning curve is much easier with silver soldering than for welding!
@@RonCovell - I've watched a lot of silver work on Paul Brodies channel and I've always wanted to try but I don't have a garage or shop to work in so I'd most likely be in my basement or outside so a welder seemed like a better option...
Welding is a good option, but I don't see why you couldn't silver solder in your basement or outside. An oxy-acetylene outfit should be less expensive than most welders, also - and it's great to have one for heating stock for bending.
@@RonCovell - That's actually a good point... It would be a good place to start, I might have to look into that as an option instead of diving into MIG without any real practice. Thanks again.... 😁
I don't know what kind of bicycle you want to build, but for a lightweight frameset, MIG welding is not a good solution. These days many bikes (like cruisers, and e-bikes) are made from heavy-wall material, and MIG welding could work for those, but for the traditional bicycles where weight is an issue, thin wall tubing is the norm, and MIG just isn't the best process.
Thought for sure that you tapped Phil Wood on the shoulder for the spokes. Special thanks for sharing the entirety of the learning curve associated with the tool development!
I worked with a local bicycle shop on this project - Watsonville Cyclery - and they have a Phil Woods thread rolling machine. It's a masterpiece of engineering!
the kink from the first jig was because the hole was on the centre of the intersection. Offset the hole so that the spoke is supported around the bend.
I hadn't thought of that, and it's a good idea!
Very nice! I'm sitting here thinking "man, that's a lot of twisting on those fasteners..." considering you have a good quantity of spokes to make. So my mind start turning... perhaps a much coarser pitch on the threads so a quarter or half turn tightens/loosens... and some type of weak spring between them to make taking it apart for the next spoke... Nothing says amateur like over-engineering a simple device, right? Thanks again so much, I do find your videos really satisfy my inner machine shop guy.
Well, I'm glad you're thinking!
That was cool! Thank you! RWB
Glad you enjoyed it!
When will you do a shop tour?!
Well, it's on my (very long) to-do list!