First post here, you all seem like a bunch of nice folks!
Originally Posted by Bikeguy Joe
Maybe there is a burr or other sharp edge in the hole where the spoke goes through?
Clearly there is an issue at the point where the spoke contacts, not the spoke itself.
The hard part is the smallish diameter hole, and deburring/chamfering without causing other problems.
Typical reamers or countersink tools aren't that small. And you certainly don't want to use anything abrasive....perhaps something like a brand new center punch or awl or something smooth
and pointed that could chuck into a drill and press into the hole. The idea being to "roll" the sharp edge outward.