I can't relate to X Y ad Z without the book in front of me but a 140 OLD is not right. Mountain bikes are 135, road bikes 130, tandems 145 and some downhillers 150mm.
595 ERD is possible. That means it is a reasonably large profile 700C rim.
I was just pointing out that 140mm oln is a hub size it was the old tandem size.Yes, but he said Giant PR-2, those were all 135mm MTB IIRC. There is also 142mm with 10mm through axles but not on those era Giants. I'll be very surprised if it is 140mm and being skeptical makes the difference between getting the right spokes first time and ending up with a batch of spokes that won't work. Where is the 140mm used? Can't say I've ever come across such a bike.
.. Guess I don't have the tools for the job at the moment!
I used a spoke size about 2.5mm shorter than the optimum,
That would be the minimum length for proper engagement. There's no problem with a mm or two above the spoke head on modern box-section rims. On old-style single section rims the final task would often be to file the spokes flush with the nipples. Remember the relatively short, threaded part extends all the way to the top of the slot.I recently used Damon Rinard's Spocalc spoke length calculator, and the results came out spot on. The spokes should end at the bottom of the nipple slots, so make sure that you measure the ERD with that dimension in mind.
The calculator calculates the exact geometric length of the spoke from where it exits the hub to where it meets the nipple's slot (provided that's how you measured the ERD). When cutting spokes you always round down, never up. Reason is that spokes stretch during tensioning and the rim compresses. If you don't round down, the spokes tend to go past the nipple's slot which isn't really a problem other than you can't use a screwdriver to remove a nipple with its flats stripped off. I'm just fastidious, I don't like protruding spokes.Was there any particular reason to do that or you had some spare spokes?
....I went along to my LBS in BKK and showed him the length of spoke I needed. He didn't have that exact size (no surprise), and gave me a bunch of them at 2.5 shorter. He knew from 60 years of building wheels that these would do the job. Any future builds I do will be the same - a tad shorter than optimum. If I went for the next size up I'd have to file or grind back the spoke protrusion from the nipples - no big deal, but why bother, just get shorter size instead. Once you've screwed the nipples onto the spokes 3 or 4 turns, you're not gaining any more strength, if you see what I mean.....