Originally Posted by
harshbarj
I can say looking at the side, the spokes look straight. The bend is pointing out.
The wheel is assembled correctly and not backwards. The holes that point to one hub side go to that side. I verified that with one of the broken spokes. This guy does know how to build wheel, he's just not that familiar with building larger utility wheels with an IGH.
The nipples themselve almost don't move in the hole. They can't really point as far out as needed which is the problem and why the spokes are breaking at the nipple. The wheel is built with thicker spokes (~2.5mm).
Ok, so if the bend is outwards to the side, then the 2x or 3x isn't the issue. Several of us plunged down the wrong rabbit hole.
It sounds like part of the problem is using oversized spokes/nipples with the eyelets, and the oversized nipples aren't tilting as much as one might otherwise expect.
It should be reasonably quick and easy to choose an electric drill with a bit sized for the nipples, and hand-ream every spoke hole to the approximate size/angle that is needed, although I don't know if the eyelets would cause a problem. But, worst case, they'd just act like nipple washers.