We know this one is a few years old, but unless you’re deep into the cycling scene, there’s a good chance this is the first time you’ve heard of [Ali Clarkson’s] foray into home made rope spokes.
The journey to home-made rope spoke begun all the way back in 2018, shortly after the company Berd introduced their very expensive rope spokes. Berd’s spokes are made of a hollow weaved ultrahigh molecular weight polyethylene (UHMWPE) rope with very low creep. They claim wheels stronger than steel spoke equivalents at a fraction of the weight. Naturally forum users asked themselves, “well why can’t we make our own?” As it turns out, there are a handful of problems with trying this at home.
There are a number of ways to skin this proverbial cat, but they all center around some very special nautical ropes, namely, Robline DM20. This rope has excellent wear and creep characteristics, in a hollow weave much like what Berd developed. The hubs also require the addition of a bevel around the spoke holes to prevent wear. Beyond those two similarities, there are quite a number of ways to lace the spokes between the hub and wheels.
However, a number of other methods have been tried on the forum threads. Namely, a number of users have attempted to varying degrees of success putting a length of spoke inside the hollow rope weave and “Chinese finger trapping” it together. The key issue here is sourcing a glue strong enough to hold the spoke piece on at lower tensions, but flexible enough to not crack with the cyclical loading on a rim.
Ultimately, this is a great look at the properties of some extremely special rope. This also isn’t the first time we have seen strange bicycle wheels made with UHMWPE.