Originally Posted by bumknees
Otherwise, I guess I'd have to "unbuild" my wheel to send it back...
Call and talk to their customer support folks as well, just to get your name in the system and to start a dialog. I've always had a good experience in working with Phil Wood on this type of stuff. They may have a silver bullet diagnosis with a better prognosis than what my history bears out.
Also, you won't necessarily have to unbuild the wheel either even if the hub needs to be looked at. Shipping will be a tad more expensive, but they can look at the hub just as easily when it's mounted as to when it's not.
When I had the problems with my '98 wheelset we actually swapped wheels: they sent me a loaner in a PW box and I shipped my wheel back. Unfortunately, as already noted, the fix didn't fully solve the problem once we had our wheels swapped back so instead of sending it back again for them to rebuild I simply asked for the hub and did the rebuild myself.
Anyway, like I said, give 'em a call in tech support and see what they suggest. If nothing else, you at least know that it's not a unique problem nor a recent one. It's also not terminal as best as I can tell from our experiences.