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  1. InigoPatinkin on

    Looks like the cassette was not tightened properly. That would lead to the sprockets moving and causing wear on the freehub.

  2. This is very common for aluminum DT Swiss freehub bodies. You can file down the rough spots and use a higher end cassette where the cogs are on carrier and not loose. DT Swiss also sells steel free hub bodies if this is a common issue for you.

  3. File the burrs on the hub down gently, grease it properly and tighten the next cassette you throw on there to spec and stop putting down super watts with your monster legs. It will be fine. I’ve been riding a fulcrum wheelset that looks like this for a while now no issues except some minor frustration getting an old cassette off and a new one on. This happens with aluminum free hubs a lot- just send it.

  4. It’s normal to have deep gouges evenly throughout an aluminum freehub body. Pretty much in this pattern and distrubtion, but often a lot deeper: https://www.reddit.com/media?url=https%3A%2F%2Fpreview.redd.it%2Fz0ruz3qtifca1.jpg%3Fwidth%3D3024%26format%3Dpjpg%26auto%3Dwebp%26s%3Dcfe994953f7f7bbb21d8110064f3d3cb99452bcf

    I’ve never seen it wear like yours. I’m assuming it was caused by failing to properly tighten the lockring, or the absence of a needed spacer.

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