• i've built a few wheels and always rounded down (and sometimes still got the spokes popping out of the nipple a wee bit)..

    I'll second that! I've never had any problems with rounding down the calculated spoke length, let's say 1½ mm. I actually did so on the last wheel I build this summer using the Edd spoke calculator, and ended up with the spokes ending flush at the nipple ends.

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