I've built about a dozen wheels and all have gone well with no follow-up maintenance needed.
I built a new wheelset for my Surly Disc Trucker and am having a problem with noise from the rear wheel under low-medium pedaling torque. No noise when braking. It sounds like the creak heard when stress relieving a wheel except the wheel is true within 0.5mm, evenly tensioned and repeatedly stress relieved. I determined it was the rear wheel after going crazy replacing all the parts on the bike and finally silenced it by using a different rear wheel. I can 95% get the noise to go away by increasing the tension but I'm not comfortable with the final tension - 142kgf average - when I have built 10 quiet wheels with the same rims/spokes/nipples using only 110kgf. I suspect it is the spokes rubbing under load but that's just speculation (no idea which side or both).
Any ideas? Maybe I need to get aggressive bending the spokes for a better spoke path?
The wheel is 36h Shimano XT hub to Mavic Open Pro CD rim with DT Swiss 2.0/1.8/2.0mm spokes and 12mm brass nipples. All new parts. The wheel is laced 3x using Shimano's recommended pattern for rear disc hubs (DS pulling spokes heads in, NDS/disc pulling spokes heads out). I can post a picture of the wheel if it helps.