"Working With New Spokes-Part1"
From time to time someone will write in saying they are having problems installing brand new spokes, so I re-post these pictures and try to explain the problems I encountered in the Summer of '2000 and what I did to solve the problem. The pictures included are numbered 1 through 5 going clock wise from the upper left photo.
Picture number 1 shows a set of older spokes placed around a Model T hub. Notice how well the butt end of the spokes fit tightly around the hub and there are very small seams where the angled sides of the spokes match together.
Picture number 2 shows a set of 12 brand new spokes placed around the same hub, note that I had already sanded and sealed the spokes with three sessions of Marine Spar varnish. I should have checked the fit first!!! Not only do the spokes not fit the hub notice the huge gap left at the top (Darkened area) This was a great puzzle!
Picture number 3 compares an old spoke to the new one. Not only is the new spoke longer by almost ¼" it is not rounded to fit the hub like the older used spoke.
Picture number 4 shows the fix. I used a "drum" sander to not only shorten the spokes, but at the same time rounded the butt end of the new spokes to match the hub.
Picture number five. All 12 new spokes fit together in a perfect circle with no gap and are ready to install.
After all of this occurred I called the parts vendor and asked how these spokes could be made this way and was told that most were made longer to accommodate rusty, bent Model T hubs and rims. I wish they had sent a note to this effect with the spokes!!! I Hope this helps…Michael Pawelek

Part 2