Hi All!
Seeing the weather forecast is calling for nighttime lows of -10°C/14°F this next week -- and my unheated garage workshop isn't going to get any warmer -- today seemed like a good time to tackle the problem of retaining my spokes in the Nomad's new Thudbuster LT.
It appeared the 'post was too short for the spokes, but the solution proved surprisingly easy once I got my mind wrapped around the problem. The Rohloff hub spokes fit okay, but not the longer ones for the SON28 (New) dynohub, and I couldn't accommodate more than 3 spokes with the nipples attached in any case.
Why?
The post is forged before it is machined, and the shaft-end with the lower link pivots has been machined so it ends in a dome shape ( /\ ) internally. All six of my spare spokes fit only without the nipples attached and only if the threaded ends were all crowded into this dome.
The solution was to package the nipples separately into a little zip-top bag, then bundle the threaded ends of the spokes into a single vinyl thread protector (cap) to prevent thread/'post damage and still allow the lot to crowd into the center dome of the upper 'post end. I just used a cutoff section of thread protector to bundle the spoke heads so they wouldn't rattle.
To keep everything in place, I then took a No. 5 (1-1/16in) rubber stopper, line-bored it, turned it down to 23.5mm OD and then parted it at 9mm thickness before evenly sanding flats to reduce the plug to 20mm at its narrowest to accommodate the front/rear butts Thudbuster use to keep the post light yet strong (the 'post is not round inside, so a round plug won't work). I then fitted a 5mm buttonhead machine screw, a couple stainless fender washers to compress the plug, a pair of internally-toothed lockwashers, and a stainless wing nut rethreaded to 5mm x .08mm. I then hammered the last thread closed to make the wing nut loss-proof and...done.
The spokes ride silently with no rattles and the plug is very secure and won't fall down the seat tube even on rough roads. I left the compression bolt threads a little long so the unscrewed wing nut makes a nice handle to easily extract the plug. With the plug removed, the spokes simply pull out along with the little sack containing the nipples.
Nice to have a "clean" solution for carrying spokes with the Thudbuster LT. This same method worked well for Sherpa and the Nomad's previous rigid Thorn/Zoom long-layback 'posts and I wanted the same for the sus-post. This method would also work with a Thudbuster ST provided the spokes extend through holes drilled in the rubber plug. One shouldn't need spare spokes very often with well-built wheels, and this solution keeps them clean, unbent, and ready to hand when needed, requiring only the seatpost clamp bolt and the wingnut be undone to access them.
By the way, care should be used to avoid disturbing the paper sticker inside the seatpost, as this is the serial number Thudbuster use for warranty validation and for determining service parts. At 9mm thickness, the plug clears the sticker nicely.
Best,
Dan.
