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@roboto
Update.
Breakthrough on the cog situation. I sanded down the anodising on both sets of threads and cleaned out the debris. I then wrapped a small length of chain around the teeth so I could turn the cog backwards and forwards by hand without applying too much pressure from a chain whip.
After a few minutes of turning backwards and forwards I finally got the cog to the end of the hub threads and it now screws on and off easily. Panic over!
Spokes should arrive tomorrow. Wheel building weekend is go.