wheel building, help URGENT
 

I have driven about 1000ks on a recently rebuilt 18 inch wheel on an 93 XT600e. Two days ago 2 heavy duty spokes broke they were replaced then the following day 3 spokes broke. I am running out of spare spokes, this before any off road riding, anybody got any good ideas. I am in Rabat, Maroc

probably too much tension on the spokes.
do not attempt to adjust the rim by applying too much tension on spokes.
deformed rims cannot be adjusted by this.
it is very important that tension is equal for each spoke. they have to sound equal when striking them with a wrench.
connect the spokes where they cross each other with a piece of wire or plastic cable straps. if one breaks, it cannot destroy something else.
good luck,
klaus

This is hard to teach from afar, but in case you are unsure what "too much tension" is - and Klaus is right on - the spoke should "ring" with a high tone when tapped with a wrench. But how high a tone?

Loosen the spoke until it goes "thunk" and definitely isn't a ring. Tighten a half turn at a time until it first goes "ding" and you're there. Most beginners way over tighten the spokes.

Adjust to this tone, and when trying to true the rim - don't be too fussy, a 1/8" wobble is plenty good enough unless you're an expert at trueing wheels - make sure you loosen as many spokes as you tighten, and by the same amount. In other words, maintain an overall equal tension, do not continually increase tension.

Then as Klaus suggests wire the spokes. Two loops around the junction and twist the ends together tightly. This will also increase the overall strength of the wheel significantly.

Thanks Klaus and Grant

Will give your ideas a go.

Regards
Ian