Between the many types of bicycle spokes, the most common would be the Standard Round Spoke (2mm). Most hubs have holes that accept these spokes, which are 2.5mm (±0.1mm) holes. A different spoke shape example, is the Bladed/Aero Spoke, which is not always hole-compatible with the Standard Round Spoke.

Many Bladed Spokes have a 3.2mm width, which means they cannot pass through the 2.5mm hole. The best approach is to use a hub that has its holes milled into a shape that could accept the special spoke.

Through the last years, I encountered the situation where I needed to fit Bladed Spokes into standard round hole Hubs a few times. I usually milled the hole by hand, with a Dremel.

In search for a more consistent, safe and even result, I developed a Jig that relies on the technologies and parts that I had at home: 3D Printing, Fasteners and Linear Bearings.

The Jig was printed in PETG, assembled and tested successfully. The end-stop screws worked flawlessly so all the cuts were similar and consistent.

After cutting all the 72 holes, the hubs were ready to assemble. The all-Japanese build includes Shimano Dura-ace HB-7600 Track Hubs with Hoshi Aero 2 Spokes, mounted on a pair of Araya RC-540 Rims.