Ferrari 156: lacing up four 72-spoke wire wheels

A few days required for this! First the hubs need to be drilled out to take the 0.40 mm (0.015") spokes; 288 holes all told. The Dremel is overkill, even with the variable speed drive provided by a sewing machine pedal, and leads to broken bits (three so far in the course of two wheels). So a lot gets done with the pin vise. Perfect for listening to the government's Fall Economic Update on the radio.

 

 

Then the spokes need to be fed in according to the instruction sheet. First, though, it is important to clear the workspace and ensure that only critical tools and supplies are close at hand, with everything else put away. One critical item (the 4X magnifier and desk lamp) is not shown. Working over a small tray also prevents bits bouncing off the bench and into the aether. 

 Once the hub is drilled and the hub and rim are mounted in the fixture, the sequence is:

1. Put a small bend in the end of the spoke

2. Insert spoke through rim. Dab with CA glue.

3. Poke into hole in hub, perhaps using pliers to assist.

4. Dab CA glue on spoke at rim.

5. Slide nipple over spoke and push through the rim until flush.

6. Repeat for the remaining 11 spokes on that row.

7. Trim excess spoke lengths with nipper.

8. Slather CA glue along inside of rim.

9. Have a sip of wine and take a breath.

10. Repeat for the 5 other rows. 

11. Slather 5-minute epoxy around the inside of the rim. It may be inelegant but it will never show once the tyre is mounted. 

 

 

The first wheel took about three hours, just to spoke it. Figure 5 hours total with the drilling and fiddling about, but subsequent ones should be faster.

OK, one wheel finished. 72 spokes, 72 nipples, rim and hub = 146 parts. Add the tire inflation valve and it will be 147. There are some mistakes (I'll let you find them), and I discovered potential future shortcuts which I will chalk up to experience in order to do better on the next three.

 

 

Next a rear wheel, which worked out a bit better and faster.

 

Update, 2020-12-02: All four wheels are done and it sits nice and square.The last two were definitely done faster than the first two, and have fewer flaws.

It's beginning to look like a car. Stay tuned!