DIY wheels again - EX511 Koozer 450 hd - heavy duty wheels

[borysgo2]

Hi all.

Yes, yes.... I have made another set of wheels. This time something strong for heavy duty use. Long story short:

BOM:
-2x DT Swiss 29'' EX511 32h rims
-set of koozer 450 hubs 120hd
-32 D-light J-bend spokes - 292mm long
-32 Race J-bend spokes - 290mm long
-64 Sapim brass niples
-a bit of spare time

The costs:
-rims - about 160eur
-hubs - about 90
-spokes - about 90
All in about 340Eur


First a bit of math:

Front wheel 3 cross


Rear wheel 3 cross


A few pix from lacing procedure:








Good news is that wheel-set is lighter than a barrel of Jameson but it weights a hefty 2,2kG.


The rear hub looks promising, steel axle, double row (wide) bearing in freehub body, 3 tooth pawls. Hope all of that will last for a good bit under a heavy rider on heavy e-bike.





More news soon...

Regards

 

[Sayonara]

What made you choose that specific hub from Koozer? Many people on these forums have bought wheels with xm490 pro hubs and been very happy with them.

 

[borysgo2]

What made you choose that specific hub from Koozer? Many people on these forums have bought wheels with xm490 pro hubs and been very happy with them.

I have marked a few stars on the picture.
Bigger flange diameter will form a stronger triangle = stronger wheel.
Freehub inner bearing is always first to go in my case, so double row bearing should make thinks easier.
Steel axle also will be stronger.
120POE (points of engagement)
I am only not sure about one thing, how well is the hub sealed up. In Ireland I can not complain about lack of water so we will see.

450 hubs are released a few months ago and are a newer construction than 490pro.

After bit of thinking, as a rear rim, FR541 could be better/stronger.
I weighted EX511 rims and there are 612g each, roughly the same as FR541.

 

[Sayonara]

I have marked a few stars on the picture.
Bigger flange diameter will form a stronger triangle = stronger wheel.
Freehub inner bearing is always first to go in my case, so double row bearing should make thinks easier.
Steel axle also will be stronger.
120POE (points of engagement)
I am only not sure about one thing, how well is the hub sealed up. In Ireland I can not complain about lack of water so we will see.

450 hubs are released a few months ago and are a newer construction than 490pro.

After bit of thinking, as a rear rim, FR541 could be better/stronger.
I weighted EX511 rims and there are 612g each, roughly the same as FR541.

View attachment 146607

Thanks for the detailed answer!

The xm490 pro boost hub also has the same CrMo steel axle! They both have it in the rear.

Looking forward to hear your experience with these hubs!

I was sad to see they did not offer the 490 boost hubs in colors like they offer their other hubs. I now see that you are able to get these new 450 hubs (model #8260 front, #8265 rear) with colors as well! I need to find a buyer for my old wheels so I can get these in purple!

Thoughts on the SunRingle Duroc rim? Been quite happy with my Duroc 35.

 

[borysgo2]

Thoughts on the SunRingle Duroc rim? Been quite happy with my Duroc 35.

My thoughts on sunringle rims are very simple, EX511 costs 77eur (fast delivery about 15eur for whole shopping) in bike discount de store. SunRingle at aliexpress cost 51eur + 22eur for delivery (long waiting time), I see no point of getting sunringle rims.

Better, stronger, cheaper --> look at the new newmen performance 30 rims or beskar 30 rims.

Regards

 

[CarolinaCrawler]

I wish we could get DT Swiss rims that cheap in the USA. Most places want $150 for any DT Swiss rim.

 

[Slaine]

Is the tools to build wheels on AliExpress is enough for this kind of Project?

 

[borysgo2]

Is the tools to build wheels on AliExpress is enough for this kind of Project?

Yes. There is very little tools neaded.
Get T handle spoke wrench 3.2mm square for sapim nipples. Stand for truing wheels is not neaded. Instead You can mount the wheel in the frame and use zip tie as a guide for truing. "Dish" the wheel, rotate it 180 deg [so the drive side will be mounted on disc side] and dish the rim again. Than true it. Job done.

Ps
DT swiss rims are coming with phr washers, do not need to buy them separately. Alu squorx nipples included with rims are not so good.

 

[Sayonara]

I guess you will still need some sort of tool to measure spoke tension?

 

[borysgo2]

I guess you will still need some sort of tool to measure spoke tension?

Yes.
The easiest/cheapest way is to buy some tool on ebay or aliexpress. Use that tool to measure about 5-10 factory wheels to compare roughly what value You should expect. The calibration of the tool is not so important. Most important is experience + even tension of the all spokes.
Cheap tool costs from 15eur to about 50eur.

Regards

 

[YZDude]

I’m a heavier rider with a moto background, so my comfort zone is at fairly high speeds into rocks and logs. So far, my EX511 with just DT350 hubs have been unbreakable.