the spoke lengths I sent you were for 3x lacing. Why are you going with 2x and 4x?
don't forget to champher the spoke holes.
also the distance between flanges appears wider?
Today's work will be to finish the flanges, including the chamfers.
Securing them on the barrel and re-lacing to see how they fit with no 'give' in the flange plate.
The 4x is the original pattern of the wheel. It will be used for the outside spokes.
I was surprised when I laced up the mock-up flanges that I only got 2x for the inner flange.
The 2x is the only pattern where the spokes fit correctly. (using the 6 1/2" spokes)
There is no change in the 2 1/2" ID distance between the flanges. Due to how things fit together.
(the two spoke flanges, the disc adapter flange, and the axle/axle barrel length).
When I get the hub flanges made, I will try to see if there is a chance the 7" will still work, thus creating a 3x/4x pattern.
But I'm doubting it. Maybe it would work if I had the 6 3/4" (172mm) spokes, but I would rather make the hub diameter to match with the spokes that I already have. So at the present the major variable is just that, the diameter of the flange.
The final answer will come as I continue to narrow down the inner flange diameter.