[Montanabill]

Lacing wheels is a challenge sometimes and trying to visualize over the internet is really a challenge.
I would verify the length of all your spokes and make sure that is correct, then closely examine the bends for inner and outer.....it doesn't matter what things are labled out of the packages the actual piece has to be right.
Fitting non stock spokes in old hubs sometimes takes a gental whack with a dead blow hammer to get the bend right at the hub. (this comes under advanced hammer use, beginners beware) Make sure the spoke head fits into the holes in the hub nicely. Did you compare the new spokes with the old spokes for length and bend?
You mention that the new spokes are larger diameter so that could be an issue....I have had to drill the holes in the hub larger to fit a larger spoke and have everything fit.

Long ago as part of a week long factory mechanics training we had to lace and true a wheel and most of the class took the wheels back to their motel and worked long into the night to get them assembled and close to being true.

 

[Montanabill]

The lengths of the spokes are the same and I did not have to drill out holes to get them in. The apple all fit nicely in the holes. I did end up using all 18 of the original “thinner” outer spokes and they went in without a push and did not have near the bow the news ones had. They also straighten up after a couple turns of the nipple. I believe the chrome coating on the new spokes was the issue. The original shine up but do not have as thick a coating on them . Also, all spokes had the same angles. This was just a totally different experience thank the front wheel which I laced and tried in an hour. Thanks for you feedback especially since you are certified at working on them.

Just t clarify, you said all the spokes had the same angles.....do you mean the angles at the head of the spoke? If so you didn't get the outer spoke bend .
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