All spokes are laced and I've checked the crossing pattern several times. The spokes are bottomed out in the nipples and I still have little or no tension.
...have you rechecked all your measurements ? The hub flange diameter, for example.
It would be helpful if you could post a photo of your lacing pattern as well.
I do try to get my spoke calc inputs as close as I can, but if I'm in a hurry, I just use the manufacturer's ERD.
A 2mm difference in ERD gets cut in half to 1mm in calculating the spoke length.
I'm still dubious that his is the only thing going on in your problem, but you are the only one present and on site.
I am unable to identify exactly what it is, over the internet and without the hub and wheel in front of me.