FrankCrank
Old layabout
...on my next wheel build I'll use the same spoke calculator and go for the nearest size under the recommended length.
My guess is the reason spoke nipples are that length is to allow for all the discrepancies and tolerances involved. The skilled part is the truing process, but I found that easy enough with a bit of patience. I'm lucky in that my LBS has loads of spokes, and it's easy to go grab a bunch and have a play - wheel-building is nothing to be feared, and is really quite enjoyable - but don't do it with a hangover......
My guess is the reason spoke nipples are that length is to allow for all the discrepancies and tolerances involved. The skilled part is the truing process, but I found that easy enough with a bit of patience. I'm lucky in that my LBS has loads of spokes, and it's easy to go grab a bunch and have a play - wheel-building is nothing to be feared, and is really quite enjoyable - but don't do it with a hangover......