Sounds like maybe you missed a hole when lacing with the old spokes? Maybe did one side 4x and the other 3x?
This can throw you way off. I bought spokes for a 3x pattern and laced it 4x. it was all screwed up. The vid i posted in Carl's thread makes it real easy to get it right for the 3x.
A question to wheel builders.
I am guessin after you ride it a few times,the spokes will need tweekin some more?.
I've never had to do that. I'm still kind of a newb at the wheel building too but what you want to do is get some tension on the spokes and then stretch the spokes. I like to push on them from both sides with my hands until the spokes settle some. You'll hear some popping as the spokes settle and unwind.
Also helps to lube the nipples to keep the spokes from twisting as you tighten them down.
After lacing and truing, I tugged on all the spokes and pulled on them like plucking
Good instincts there Carl. Those spokes are just like a new set of guitar strings. They stretch a little and twist as your tightening them down. You want to work that all out by stress relieving them.
On my front rim for my Fastback I used 15 ga spokes which are a little thinner. I coudn't get it perfectly straight so I started pushing on the spokes pretty hard. It made some god aweful noises but when I got done I stuck it in the stand and it was perfect! Been that way since. Prolly has 50 miles on it at least.
Lots of good info on Sheldon Brown's site. Check out the stress relieving section for more on this topic.
http://sheldonbrown.com/wheelbuild.html#tensioning
Funkme that's an awesome vid. That boy looks so happy on Good Vibrations. Good job getting through the wheel build. It can get confusing.