Rim and Spoke recommendations
 

If you would be so kind as to make recommendations for the following three wheels I would be most grateful. Thanks in advance! I’ve built a few wheels and am comfortable with the process but think my results have suffered from poorly selected materials (leftovers, random new old stock). All of my wheels have lasted at least five years but all have died from cracked rims. This time around I’m happy to spend more money but only for tangible benefits.

Rider weight 160 lb; Bike – old (ancient?) Trek 1420; purpose fast commuting – small backpack or no load; hub 32h Shimano 105 9 speed

Rider 220 lb; Bike – club racer (not the model, just the style); purpose club racing (I’m a CAT nothing and won’t be winning anything but I still like to go fast on this bike); hub 32h 2005ish Campagnolo Veloce 10 speed

Loaded tourer/commuter with peak load in the 290-300 lbs range for rider, bike, and gear; 622x45ish tires, hub 36h Deore disk 9 speed

Please post rim and spoke recommendations for these wheels. I’m not adamant about keeping the hubs but these are suited to their purposes IMO and in good condition.

Any decent rim designed for the tire width you prefer. For loaded touring, where the ability to "help" the rear wheel over bumps is limited, consider wider tires as a major benefit, though you may be limited by clearance issues.

For spokes, 2.0/1.8 DB on the right rear, bit you can go lighter on the left rear and front, say to 2.0/1.6, if you want. If you want, there are also 2.3/1.8/2.0 (or something like that) spokes available, though you don't mention ever having poke issues. Lighter spokes help prevent rim cracking at the spoke holes, which why I'm suggesting them. Using lighter spokes on the left rear means you can do a better job having adequate tension on the left (thinner spokes don't need as much tension), without going super high on the right, though for your loads, I'd be running closer to the high end of the range anyway.

Wheels decently build as above, should last until the brake track wears or a serious crash whichever happens first.

I would go with BDOP's build kit and go 28 32 for the 220 lb and I think you will have a nice wheel. I built the 24/28 great wheel and I 6'2 175.

Rims: Velocity Dyad

Spokes: Wheelsmith. For the touring application, drive side (right) DH13, every where else DB14. Use brass nipples.

To help avoid cracked rims consider double walled rims with double wall eyelets. The eyelets are supported by both walls distributing spoke tension and impact stresses over much greater area.

For the 160 and 220 I would go for Mavic Open Sport with 15 or 14 gauge double butted spokes.
For the Tourer I'd go for a Mavic 319 with 14 gauge double butted spokes.