The replacement spoke I ordered came in the mail today.
It's the silver one (second from the left).
It came from a bike shop in Pasadena.
It's a used spoke but looks nearly new.
Comparing the spokes to check for length.
The silver one is the correct length.
Took off the tire and inner tube first.
Peeled back the rim tape to access the spoke hole.
There is no spoke hole!
I'd replaced a spoke a long time ago (several years ago).
Forgot that this wheel doesn't have spoke holes in the rim.
The hole on the left is for the inner tube valve.
The broken spoke is at the middle of this picture.
There's about 5 mm of the broken spoke sticking up.
Used a hammer and a punch to push the broken piece into the rim.
But, the broken piece is too long to go through.
It went down below the level of the broken threaded portion but only about 3 mm below the top.
Can see the broken spoke in the center of the hole.
Just noticed that the threads on the Mavic spokes is backwards (opposite to standard).
The bolt on the left shows the standard thread direction.
As can be seen, the spoke nipple threads are backwards.
The green packet and the white packet are extractors.
Used for removing drilled out broken bolts.
Started with the smallest extractor for 1/8" hole.
Used an 1/8" drill bit to prepare the nipple for the extractor.
Since the broken off piece of the spoke is still in the hole, the extractor could only go down 3 mm.
So, it slipped when trying to turn it.
The hole just got more messed up.
The green packet of extractors are twist type.
These don't work on reverse threads.
Drilled out the hole larger to use the next size up fluted extractor.
It started turning.
Can see the threads showing up as the broken piece is being turned.
Unfortunately, about half of the nipple came out.
The other half is still stuck in the hole!
The new spoke won't go into the hole because of the broken off piece of the nipple still being in the hole.
The broken off piece of the spoke was able to be taken out through the inner tube valve hole.
Even towards the top of the hole, some of the threads are still covered by left over nipple material.
Drilled out the hole some more with a larger bit to take out most of the nipple material.
Coated the replacement nipple with grease.
Positioned the replacement spoke for installation.
Using the Park tool, started threading in the nipple.
It went well with installing the nipple.
On purpose, didn't clean the threads on the nipple or the hole.
I wanted there to be some interference, in case the drilling was off-center and took out some of the threads in the rim, which I think it did in part.
The nipple went in tight, with good friction/resistance.
When the nipple is threaded down as shown below, there is significant tension in the spoke.
The tension seems to be holding well.
The final test is in the riding.
I think it will be OK.
These are all the tools used to do the spoke repair/installation.
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