Changing to semi-metallic pads didn't work, although maybe the honk is a bit quieter? Hard to say.
There is one issue with the (Hope Pro 5) rear hub: it has the wrong end cap. I ordered a microspline driver, but the shop that built the wheels for me put on an XD driver. Fortunately I noticed this before driving away, and they swapped out the XD driver for the microspline driver. Turns out the two different drivers have different drive-side end caps, and they left the XD end cap on. Photo of the different end caps below, note the difference in the number of steps, for example:
See also cutaway diagrams of the
HG driver (same endcap as XD) and
microspline hubs; note the differences in end cap length.
The XD driver end cap is shorter than the microspline end cap, which results in axial play in the freehub. I didn't notice this initially because the inner freehub bearing was a few mm proud of its seat, so there wasn't any play, but the dropout quickly started machining the cassette lock ring. I took the freehub off, pressed the bearing back in, and filled the gap between the outer freehub bearing and the end cap with a 2.5mm O-ring from the hardware store. This took out nearly all the play. I've also experimented with two 2mm O-rings in there, which get squished a bit when the hub is in the dropouts, so there shouldn't be any play. In both cases, the honk persists.
I'm headed back north to the shop that built my wheels to hopefully get the right end cap, and then I'll probably go on a ride and hope the honk sorts itself out. If you hear a honk in the woods around Bellingham this afternoon, say hi!
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