Originally Posted by
e0richt
this is not the case here... I can install the spoke but as I tighten it it starts to become too long and is crowds the tube... enough that it will pop the tube...
See Bill K's post.
The case you have is that the spoke is too long, get one the correct length.
The threads on spokes are rolled, not cut. Which means that the threaded part of a nipple cannot be threaded past the end of the threads on the spoke without damage to the nipple (low to no spoke tension). Most nipples have a counter bore on the end pointed towards the hub before the threads start. If you try to push the unthreaded part of the spoke beyond the counter bore -> scrapped nipple.