Thicker spokes doesn't mean they are stronger, thinner spokes are more elastic and can cope with some forces better. That's why butted and double butted spokes are used where extra strength is required. The holes in the hub are also important, if they aren't just right then they can cause the spokes to snap. A rear hub motor means a lot more force than usual can go through the spokes and will show up weaknesses that are usually missed, I found out the hard way that some bike shops (at least 2 out of three for me) don't have the specialist knowledge needed when it comes to spokes.
I hear you and agree with you (partly
)
There wasn't any substantial difference in the flange size of 1.8 and 2mm spokes. I can't do much about the hub holes as they are already drilled.
I take on board what you are saying but I stand over my work and completely confident that they are all sound.
If someone was to thread a spoke incorrectly they would actually be twisting the grain in the steel, could easily be done with an undersized die, or a split die that is tigthened too early. Many people don't back off when cutting and use an appropriate cutting oil.
Same could be said for not having the die square on the cutting surface
As for the threads, they are very good. I will take some shots with the scope and post when I get a chance.
After several weeks of hard usage (28 miles per day) all is good, some tensioning was done at around 100 miles, pretty much expected after building any wheel.
I would be more concerned with rolled threads on a wheel that is not tensioned correctly.