Re: 72 CL350 Build - updated pics and progress 10/8/12
Well, at first I thought the hub might be offset from center, but I think there is way to much difference for that. I went back and looked at your other pics, and it looks like the lacing "pattern" is correct, not sure if it is possible to actually have it otherwise. The one pic of the rear looks like the outside spokes, (that is, the spokes that come through the hub from the inside and cross outside of the other spokes) are bending, as if they have to be pulled to the center line of the rim on order to pass through the hole. Looks like all the outside spokes on both sides do this, but it may just be the photo. Is it in any way possible the inner and outer spokes are backwards? Based on your obvious skill, it seems a wild long shot, but I cant think of anything else. It is possible to have all the spokes "leaning" one way too tight, and the opposite leaning ones too loose, but that results in two in a row too long, and then two in a row too short, then two long, then two short etc. If the rim is off to on side as mentioned first, you get a long, short, long,short long . . . pattern, but it would require a LOT of offset to get so much deviation in spoke engagement. Put a straight edge on the rim and check how far the hub is where the spokes pass through. Obviously should be very close to the same on both sides. Within a 1/16" it is definitely not the problem.
Maybe take out an outside spoke just to check. If that can not be done, it looks like the "short" spokes have plenty of room to be free of the rim by spinning the nipple off. You may be able to prove this to be or not be the trouble if you can get one spoke out. Obviously the ones with the "greater than 90 degree" bend are the outside spokes.
Regardless, there is unquestionably a problem that needs solving and correcting. The long spokes could be cut as suggested, but it looks like the short ones are REALLY short, and I would be very concerned that there is not enough thread engagement. No doubt you noticed that the nipples are counter bored very significantly so the threaded portion of the spoke is concealed and protected when proper;y installed, so there are probably only a few threads actually engaged.
For the record, I have built quite a lot of wheels, ( I have 10 bare hubs on my bench as I write this, yes motorcycle hubs) and have never seen this problem without the spokes being clearly wrong. I lace up the wheel, throw it on a stand and spin the nipples almost to the top with a flat blade screwdriver. then go round and round until the spoke nearly contacts the driver. Most wheels are getting to be snug by then, and most times surprisingly close to true, making the actual truing and tightening a breeze. I do an fairly rare occasions have to grind down the odd too "long spoke, but 1/16" too long would be major, and there is usually evidence of some rim or hub issue causing the over-engagement.nothing like your situation.
Hope this helps. Your bike looks fantastic, I'm really enjoying your build!
best
John