Wheelbuilding questions tips and ponderations

Also, the spokes you ordered did come back exactly the same length as those you took out? And...the measurement was correct from the old spoke?

Do you still have the old spokes? And any photo of the bike with the wheel in you can zoom in on?

Got to ask.
I don't have the old spokes, I eventually threw them away. If I have to reveal the truth, I built up this wheel 3 or 4 years ago after the rim had been repainted. My son asked me if I could build the wheel. He had already taken it apart without taking photos, measured and ordered the spokes. I came in at the wrong end of the project. I had help of a YTvideo then but I didn't find it this time. I don't think I dished the wheel that time either, they had to add a number of washers to the hub to stop it rubbing in the frame.
I don't have a photo of the wheel before the refurb. They were actually able to ride the bike with the wheel i built right up untill this past autumn when the hub developed a crack and one of the flanges sheared off. The nightmare had returned😱.
 
The cross pattern can be any thing really, but in reality its dictated by the physical wheel.....is can you get the spokes round the hub etc. I've built 4 cross on big hubs, but it gets harder and you start to have issue on many with rubbing spokes as the fross the flange.

I would try flipping the spokes to the other side....possibly use the "all in one side" first method here as your trying to establish a fit. If 3x doesn't work try 4x.

I think the lesson here is take notes and pictures....but that's easy said and sadly you have been left holding the baby!
 
The cross pattern can be any thing really, but in reality its dictated by the physical wheel.....is can you get the spokes round the hub etc. I've built 4 cross on big hubs, but it gets harder and you start to have issue on many with rubbing spokes as the fross the flange.

I would try flipping the spokes to the other side....possibly use the "all in one side" first method here as your trying to establish a fit. If 3x doesn't work try 4x.

I think the lesson here is take notes and pictures....but that's easy said and sadly you have been left holding the baby!
I don't understand what you mean by "flipping the spokes to the other side. Believe me i always advocate the method of taking photos first and then rip it apart. It's a pity my son didn't hear that before he got his grubby hands on it. I think I have a headache coming on the more i think about it 😵‍💫.
 
put the drive side spokes in the non drive side....it just looks like the drive side might be a bit short ...and obvious the non drive side is too long.

Assuming the drive side is the small flange?
 
The other thing is to use the spoke calculator in reverse. Try out scenarios of cross pattern till you get the length of the spokes you have come out the calculator! Saves a lot of fitting.

If you can't get close, something must be wrong with your spoke lengths.
 
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