Cutting my spokes?

Part of the transformation to a motard for the XR100 includes swapping the existing front wheel for an XR80 wheel. The hub is identical but it's laced to a 16" wheel rather than the stock 19". This allows the use of matched 16" tires front and rear. I've been watching eBay for weeks for an XR80 wheel and haven't found anything but junk.

A brand new XR80 rim is only $22. So I'd like to just use my existing hub and lace the new rim to it. Unfortunately the spokes to go in between cost $3.85 each. Multiply that by 36 and it gets really expensive. I think that I can cut my spokes off and rethread each of them at the correct length.

Crazy idea? It would save me a fortune.

are they threaded on one end?
there's this option PRO WHEEL REAR WHEEL SPOKE KIT - 16? | MotoSport

Bicycle guys cut and re-thread spokes all the time, so it's possible. Make sure the spoke shaft isn't 'butted' - meaning it has a stepped diameter - Or at least that the area you'll want to thread is the same diameter as the currently threaded area.

Not sure about this, but I *think* motorcycle spokes have rolled threads rather than cut...

Definitely worth some investigation due to the safety factor...

They aren't stepped at all so no problems there.

Not sure on the rolled vs cut. I'll check. Buchanan offers a service where they'll re cut your threads for you. Only $.45 per spoke. Not a bad deal but I think I can do this myself.

I thought we only did this to people when they weren't looking?

I say just buy a bst cf set and call it done.

I'd suggest not skimping on front wheel spokes. Having them come apart while riding wouldn't be fun.

Here we go.

Every time I saw the title I had flashbacks, so I got skeered.

Sidenote hijack - I did get a free replacement wheel.

You're about to experience the wonderful, frustrating world of do-it-yourself wheel lacing. You'll probably be able to put your Surgeon's skill to good use here.

Take your time in setting up wheel 'loose', ideally you won't want to do a lot of truing with spoke tension - Especially on a wheel as stiff as the one you're working on.

Do you already have a die?

Not the right one. That's a project for later tonight. I have everything apart and polished but had to take a time out for an event with MrsSlick.

The actual lacing pattern for these wheels isn't very complicated compared to some that I've seen. I'm going to have a local guy I recently discovered do the truing.

Not legal in my class...or available for an XR100.

Hmm, can't seem to make it fit any standard dies. I'm going to have to do more searching.

What it looked after 5 min in. Then 3/4 of the way in only 30 min...then 45 min later when I had completely disassembled, and relaced correctly. I've realized that I'm not going to be able to get this done the way I want by this weekend so I'm putting it back together and it's going on eBay. I'll just buy a complete XR80 front wheel to replace it.

Oops, forgot the pics.