This DT 540 rear hub was supplied as a 140mm but the customers frame was 145mm. Thanks to Tom at Sheppards, the DT Swiss importer, for sending the necessary 145mm axle no questions ask – it’s great to have good support.
I replaced the axle and machined a new spacer which was not included with the axle. There was also a clearance problem with the disc mount – the disc rotor was sitting 4mm too close to the dropout and the disc brake was not able to adjust outwards that far. I machined 2mm from each side of the screw-on adapter and now the rotor sits where it should.
It was interesting to see the insides of the 540 tandem hub – the design is the same as the 240s hub except that the axle and freehub are made from hardened steel rather than light weight aluminium.