about brake "clearance", sometimes things change alot when weight / force is put on them.
again 1 example: I rode about a year with a split rim, inner cracked across all spokle holes, outer start to crack at one side.
the bike upside down on the ground, spinning wheel, everywhere clearance.
ride with it, a repeating noise at wheel frequency.
and not always, periods of months nothing, then sudden back.
but I started to notice it came back after replacing an inner / flipping an outer tyre. To do so, you have to deflate and put back pressure, and that return to full pressure, brought the noise back.
what happened: under load, that rim sidewall was pushed outwards and clearances dropped enough to make contact.
when riding uphill, more weight gets on the rear wheel, more force, more tyre deformation, so on..