It seems I have found the reason for my run of broken spokes. The Shaker hub needs to be built asymmetrically onto the rim, where as I had used equal length spokes on both sides. This means you need spokes with an extra 2mm on the non drive side. In hindsight this is obvious, due to the hub being longer between the flange and the axle nut on the drive side. But being used to 'flip flop' hubs, which are symmetrical I didn't take it into account.
Once again I was helped out by the great mechanics at my LBS, Wheelies. We figured it out between three of us eventually. They even rebuilt my wheel after my attempt went wrong. (My first three wheel builds were perfect I swear!)
For the record, Charge didn't mention anything about the need for this hub to be build asymmetrically, even after several emails back and forth.
Other Charge Hub stories
Here and also
Here. I have a feeling this post will not be the last on the matter!
