Bicycle Mechanics - Wheel Building Delema

to make a long story short, i took my wheels apart to paint them. I have followed http://sheldonbrown.com/wheelbuild.html and some videos on youtube they pretty much all say the same thing. I know how to lace the wheel, i have done it 4 times now. The problem that im having is that when i get everything done, The spokes are way lose. (I have kept the same spokes, hub, and rim together) When I tighten the spokes the nipples bottom out and cant be lightened any more and the spokes are still very lose. I'm at a lose as to what to do, any help would be great.

Is it possible the wheel used to be a cross 4 and you've tried to rebuild it cross 3?

Make sure that when you have laced them you have every second spoke comming from a different side of the hub. It is easy to follow the instructions and still lace them slightly out with same hubs side which will mean that spokes will stick out. Have done it myself.

U u laced it incorrectly (change from what it was b4r), the stamp-on pattern on the hub would had told u. I don't know if one should re-use spokes, they stretch? Really dunn know this one.

Spokes can be reused, and I have gotten away with so doing on several occasions, but it is probably better to use new spokes with a new rim. Yes, I think the problem in this case is simply an inadvertent change from 4X to 3X.

it is a 32 spoke hub, can i do a 4 cross?

it is a 32 spoke hub, can i do a 4 cross?

Going by the general recommendations 4X on 32H is borderline, but unless you're running a high flange hub it should be doable.
If it's a high flange hub you'll likely end up with spokes overlapping the spokeheads down by the hub.
This by itself isn't immediately disastrous, although some claim that the extra bend will cause premature fatigue in the spokes.
But it most certainly will make replacing a spoke further down the line more awkward.