OP, kindly update us when your Phil Wood hub issue is resolved.

PW FSC hubs had a bad freewheel when they first came out several years ago. PW had to replace/modify many of these hubs. This was supposedly an "old", resolved issue for years now. I wonder if you had the bad luck to get an original, unmodified FSC hub in your built rear wheel.

I'd really like to know if PW's $400 FSC hubs are fixed yet, or not.