I have successfully setup multiple sets of wheels tubeless but my most recent pair have both leaked at the valve stem. I didn’t consider there to be much variety in valve stems but my theory is that some rims have a different internal profile that requires a different shaped valve bushing for a reliable seal. Is this a common issue/ solution that others have experienced?
Yes, I’ve had the same problem. I think the main factor is the radius of curvature of the center channel of the rim. The usual rounded conical valve stem rubber seals work fine if the bottom of that channel is more or less flat. For more curved channels, the rectangular rubber (like the DT Swiss valves for aluminum rims) work better in my experience.
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I have most luck with valves that have a washer like top to them much wider than the valve hole that platters the rubber down, spreading it out and thus plugging the valve hole more effectively right the way around.
Something like these:
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