Spokes and Nipples
Traditional spoke nipples are made of brass, brass isn't a particularly strong metal, but it is a pretty heavy one. Aluminium is about a third the weight of brass, so making aluminium spoke nipples seems like a good way to save weight without losing any real strength right?
Well the problem with previous aluminium spoke nipples has usually been that they round off really easily, because although aluminium can be as strong as brass, it is a lot softer. When you slide a traditional square spoke key onto a square nipple, there HAS to be a little gap, if the spoke key fitted perfectly then sliding it on and off would be impossible. This little gap means that the key moves slightly round the nipple and just presses right on two opposite corners of the nipple. With nice hard brass this isnt usually a big problem, but with softer aluminium nipples they just cant take this and distort.
Our solution to this issue is to make a special hexagonal nipple and key.
Hexagons work better than squares for transferring torque. That's why most other nuts and bolts on your bike use them, but with a straight parallel hex getting the key to fit right would be even harder. But our nipples TAPER and so does our key. So the key slides on easy then as it slides down the nipple gets tighter and tighter fitting until ALL the gap is eliminated. This means that the key FULLY supports the nipple and spreads the load over FIVE of the six corners.
It is pretty hard to see the taper because it is very very slight, but this cad rendering might help show it.
The key itself has the matching female taper hex and is kept as simple as possible so you can keep it on your key-ring so it is always handy.
On the spokes themselves we wanted to save a little weight too, but without going as far as a traditional double butted spoke. Our solution to this was to make a very gentle transition and to reduce the section area by just 20%. We also kept the butting away from the hub flange where grind damage is most likely to occur.
We call this "semi-butting", though technically it is still a double butted spoke.
You are going to have to look pretty hard at the first photo to see the very gentle transition from one size to the other, but it is there and it saves about 15% off the weight of the spokes.
Combining these two, we can produce a weight saving of about TWO ounces per wheel. A little less on a 36, and quite a bit more on a 48. For a typical 36 front 3cross and 48 rear 4 cross you should see a weight saving of well over a quarter of a pound, without any difference in wheel strength, but that is a real pleasure to true thanks to the taper-hex nipples.

Comments
hell yea im diggin that great idea
Posted by: paul | October 24, 2007 12:52 AM
Very nice! I always wondered why nobody made tapered nipples like that. Any chance you have an expected release date? I want to rebuild my wheels soon!
Posted by: Bunky | October 24, 2007 04:03 AM
when? i want all the new stuff soooo bad.
Posted by: andy | October 24, 2007 05:55 AM
MAKE COLORED SPOKES
I WANT TO MAKE BRIGHT YELLOW WHEELSET.
DO IT!!!!
great idea.
Posted by: carlo | October 24, 2007 06:37 AM
if you don't already plan for one, please also offer a traditional (i.e. Park style) spoke wrench. working only with the one pictured will be painfully slow, especially with 48's
Posted by: Pierre Pierros | October 24, 2007 07:43 AM
ohhhh. i likeeeee.. ;)
Posted by: 'le0n | October 24, 2007 07:51 AM
Are you gonna make some stock wheels with all Gsport parts? I'd buy!
Posted by: Adam | October 24, 2007 08:11 AM
personally ive never had a problem with stripping traditional alloy nipples when using a park 4 sided spoke wrench...seems abit unnecessary but a cool idea none the less
Posted by: j | October 24, 2007 08:40 AM
Philips head on the other end of the nipples please george
Posted by: Pete Greaves | October 24, 2007 08:45 AM
yeah powder coated red and you definately will sell one
Posted by: Anonymous | October 24, 2007 10:06 AM
so the nipples are made of aluminium?
Posted by: Anonymous | October 24, 2007 10:50 AM
Nice work dude I'm fed up of alu nipples stripping it makes getting any decent tension almost impossible. Definatly necessary!
Keep up the good work.
Posted by: Rob | October 24, 2007 11:27 AM
the demise of the rounded nipple! Excellent stuff.
Posted by: mexican john | October 24, 2007 01:32 PM
erm alls seems good, but the size of that spoke tool is going to be a real downfall, adjusting a whole 48spoke wheel will take many hours. maybe work on a smaller tool ?
Posted by: max | October 24, 2007 02:32 PM
Will you be making the nipples in black? Thanks in advance.
Posted by: Daniil | October 24, 2007 02:49 PM
i have seen this so called nipple tech in many mtb wheels and bmx wheels(exp, atom lab,Spinnergy,Cane Creek)for years. there even was a nipple company a few years back that only made nipples like this. Alloy nipples work great save weight however the fatige life is less then 6 months for a bmxer. On top of that the average bmxer does not put anything on the thareds then lets the nipple seize to the thareds.
Posted by: john bob fred | October 24, 2007 03:04 PM
one of the best ides i have heard in a longggg time. great work.
Posted by: Anonymous | October 24, 2007 03:28 PM
if you want a light rim drill holes in it dummies
Posted by: justin | October 24, 2007 03:32 PM
GSPORT WHEEL SETS has to be the way
George I meet you around 96 Respect on how far you've taken GSpORT
P
DBCBMX
"Destruction Breeds Creation"
Posted by: Anonymous | October 24, 2007 04:10 PM
you should sell these on they're own as nipples not spokes and i was wondering if u use the same metal for the spokes as odyssey does and props on the marmoset hub
Posted by: clay_w_bike | October 24, 2007 04:51 PM
Brass had been traditionally used for its ability to sink with other threads. Aluminum just doesn't seal the same way, so wouldn't this cause a problem with your wheel staying true?
Posted by: andy | October 24, 2007 04:56 PM
"john bob fred"
no you haven't.
What you MIGHT have seen is things like the (now defunct as far as I am aware) Spline Drive nipples, or the new oversize parallel hex nipples that Shimano are using on some of their downhill wheels.
The spline drive nipples require the removal of a LOT of material to create the splines (which weakens them), and since they are not tapered there is still an issue with tool fit.
The Shimano nipples which only came out recently (as far as I am aware) are also NOT tapered.
If you are thinking of some other type then please feel free to post ANY kind of reference or searchable data to back yourself up, alternately feel free to email me.
Neither my own searches or the patent agent's or the patent office's found any prior art with which this might conflict...
Posted by: George | October 24, 2007 05:07 PM
How much
Posted by: hank | October 24, 2007 05:57 PM
fag
Posted by: Anonymous | October 24, 2007 07:40 PM
Will they come in black?!
Posted by: Jens | October 24, 2007 09:25 PM
http://atomlab.com/bmxnipples.html
Kind of like these?
Posted by: James | October 24, 2007 11:08 PM
^^^ in that they are spoke nipples, yes.
But those are clearly; both square rather than hexagonal, and parallel rather than tapered.
You DO realise that I never claimed that these were the first ever spoke nipples...
Posted by: George | October 24, 2007 11:38 PM
Morning George...
Will there be any issues with certain rims that dont conform to the standards...
I mean if a person buys a rim that does not allow the full length of the hexagonal section to appear out of the rim hole, will this mean the hex key doesnt sit properly at any point on the hex?
On a normal spoke this would be no problem of course, but as you say, normal spokes are not perfect.
If this is not an issue, just ignore this!
Posted by: Owen | October 25, 2007 12:16 AM
"You DO realise that I never claimed that these were the first ever spoke nipples..."
"so the nipples are made of aluminium?"
best quotes so far
Posted by: bro-g | October 25, 2007 01:35 AM
Will the nipples and spokes come in black?
Posted by: Daniil | October 25, 2007 08:24 AM
can the tool spin freely between 2 spokes on a 48? if not please redesign a smaller one, because the only shop i let true/tension my wheels wont touch my wheels otherwise (and it would be a pain for me too)
Posted by: Anonymous | October 25, 2007 10:40 AM
Hi Owen,
What rims are you thinking of? I cant think of any rim that holds the spoke nipple THAT far from the outer face. They will certainly work with every BMX rim I can think of.
Black (and other colours) WILL be possible and it IS something we expect to do fairly soon. Black will probably be a launch colour.
The tool will NOT spin freely in the gaps on a 48. It will on a 36 though. I did want to make this an option, but it is very uncomfortable to try to put any force on a key this narrow. However, I DID design it such that the key can simply be cut down on the long arm to clear (the short arm WILL clear on a 48 no problem) so to customise your key is very simple and it will still fit on a key-ring.
Posted by: George | October 25, 2007 11:34 AM
very awesome george.
i am stoked.
why are people stupid?
i expect an answer. if not thats cool aswell.
Posted by: Anonymous | October 26, 2007 03:32 AM
how come its not on a gsport rim ?? damn george could have told me i blazed out £18 on ali nipps hahah and some of them av rounded off hahaha
Posted by: jersey | October 27, 2007 05:02 PM
Sounds fresh man.
Posted by: Mitch | October 28, 2007 03:24 AM
plegs out by x-mas?
Posted by: john | October 28, 2007 04:16 AM
PLEGs are STILL in development. We are making progress and I hope to be able to give a relatively firm release date later this year for sometime next year... but right now nothing is certain.
Rest assured when we have solid news we will post it.
George
Posted by: Plegs not yet | October 28, 2007 06:18 PM
galvanic corrosion?
what about this pain?
Posted by: Anonymous | October 29, 2007 01:20 AM
any release time on pleadals yet?
Posted by: Ambrus | October 30, 2007 12:04 PM
I know DT makes a hexagon nipple. But I think they use less material(possibly weaker) and it is not tapered.
Posted by: Nic | October 31, 2007 08:39 PM
Why are these necessary? Double butted spokes from dt are great. Alloy nipples strip for a few reasons.
1. Too much tension
2. They have siezed from cold welding and when that happens they should be replaced.
3. The nipples are simply bad quality.
Yes the nipples "could" make the wheels last a through an extra truing, but if a the spokes and nipples dont match the quality of dt, marwi and wheelsmith, they wil be just another bmx product that gets thrown out, after they sell out. Please explain why using the proper tools isn't all thats needed? Why is it we are so lazy and cant learn how to properly do something?
Posted by: Steven | October 31, 2007 10:02 PM
hey man, take it easy, george here is just trying to improve the quality of our bikes as much as he can and he's doing a great job of it. He's being innovative so there's one less thing on our bikes that we have to worry about, thus making us lazy.
Posted by: lucas | October 31, 2007 10:52 PM
Hi Steven.
ALL traditional square and hex and other shape nipples HAVE to have a slightly loose key. If the key fit "perfectly" it would be impossible to slide it on and off.
At such a small size, even the smallest bit of play is a BIG problem. 0.1mm may not seem a lot, but as a percentage of 3.2mm (the distance accross flats on a normal square nipple) it is very significant.
DT spokes are pretty good yes. However getting double butted ones in a length suitable for BMX is often not easy and when you do find them they tend to be expensive, like $1 per spoke. They are also simply based of a design intended for road or mountainbikes rather than having the butting position tailored to suit a BMX wheel that may well be used for grinding and get big side loads from 360's and tailwhips etc.
I have been building bike wheels for over 20 years now, and this is an issue that has always existed and many many people have mentioned to me... There IS a problem with existing designs, and this IS the solution...
Posted by: George | November 1, 2007 11:16 AM
i love the hex design, and the way they are tapered, but i don't like aluminum nipples because they cold weld to the stainless. if you make a set of them in the good old fashioned brass i would run them. but i know that won't happen because it would make them "to heavy" we are only talking about ounces here. to me, any bike below 25 pounds is way to light. mine is 28, and thats supper light to me.
anyways, i like the design, i just don't like aluminum nipples.
Posted by: chet | November 1, 2007 06:35 PM
G-sport is the current leader for some of the newest and best designs for BMX. All these companies come out with cool designs but they are not practical. G-sport has the most practical designs that i have seen in a while. Although g-sport doesnt focus on main parts (bars,forks,frames,stems,etc) they are improving the little things on our bikes. I beleive this just pushes this company that much further into the new realm of BMX. G-sports parts are of extreme quality and I would expect no less from these new spokes and nipples.
I recentely built myself a new wheelset with g-sport rims. I had a huge problem with using the alloy nipples and having them strip out. I love having a ton of spoke tension and putting all that tension on regular alloy nipples stripped them out rather quickly. I will be changing both spokes and nipples as soon as the become available.
Good luck to you with your quest to improve my riding experience.
Much respect,
Scott
Posted by: Scott | November 5, 2007 07:09 PM
you might want to make the spoke wrench out of titanium... the weight weinies are going to complain there keys are too heavy.... hahaha. this is a great idea, im suprised that no one thought of it befor. i bet there going to cost an arm and a leg though. what ever happend to the steel pegs you were going to make??? they have been on the site as "classified" for a few years now.
Posted by: matt | November 5, 2007 09:43 PM
agreed..
please please please...
make complete wheelsets in colors...
i love your stuff...
btw
Posted by: anthony | November 7, 2007 11:02 PM
Please make them in color options. Please lots of colors
Posted by: Deven | November 9, 2007 06:57 PM
pledals are the real thing!i hope they wont take as much time as the plegs.any idea about when they might be available?
Posted by: ambrus | November 10, 2007 12:24 AM
Do you make spokes for 24" wheels, & any specific for a range of your hubs (e.g. vandal hub)?
Posted by: Chris | November 10, 2007 06:25 PM
hey george. why dont you put some rubber inside the nipple to make the nipple like the dt prolock?
Posted by: chosas | November 12, 2007 01:58 PM
"Although g-sport doesnt focus on main parts (bars,forks,frames,stems,etc)"
aaahem director forks/ elementry stem!
Posted by: nate | November 13, 2007 06:59 PM
^^^ thats branded under odyssey not G-sport.
These sound like a pretty good idea and are the nipples 7000 series aluminium?
Posted by: Anonymous | November 13, 2007 08:54 PM
all about hex and pressure lately huh?
keep it up.
Posted by: bostongeorge | November 14, 2007 12:26 AM
when will they be out to buy and how much will they cost
Posted by: Norby | November 21, 2007 03:51 AM
hey guys dont market ur cristmas gift stuff hear no one cares
Posted by: Norby | December 5, 2007 06:35 AM