Cassette eating into aluminium freehub

[Elliot M]

Hi all

The cogs on my Ultegra cassette are biting their way into the splines of the aluminium freehub on my DT Swiss 240 hubs.

It's the 2nd,3,4,5 smallest cogs which are individually mounted, which are the issue. There's now significant movement.

Has anyone else encountered this problem and how did you resolve it?

Having Googled a bit, seems options include:

buying an American Classic steel clip which goes between loose cogs and freehub, only available direct from AC

DIY version: supergluing suitable thin steel strips to the load bearing edges of freehub

switching to SRAM Red one piece cassette (£££)

replacing the freehub, doing up the lockring really tight and hoping

[Phil H]

Or don't pedal so hard.

The correct solution, as always, will involve buying something new and shiny.

Not sure that will fix your MySQL problems though.

[Elliot M]

Hmmm, that's a forum issue - I'll PM Marco.

There are about 50 DBAs sitting behind me but I am not sure they will be interested.

[Ivor]

[quote="Elliot M"]

replacing the freehub, doing up the lockring really tight and hoping

[Grahame]

I had the same on my Bontrager-branded mountainbike rear wheel (effectively a DT hub with different transfers). I cured it by switching from XT to SRAM 980 cassettes. Then the rim broke.

[Elliot M]

Wrote a longer reply but feel foul of DB issue.

Freehub is 2 years old, but works fine, but looking for permanent solution.

AC's clips do seem to be the thing (illustration PDF: http://www.amclassic.com/documents/help ... ltegra.pdf) but may not be imported.

Will try to locate and if not will go for SRAM midrange cassette instead.

cheers.