Just a guess here, but did you get new wire?
Sounds like new smaller diameter wire, per gauge?
Also, if you are winding faster, are you winding looser?
On HB Pickups, I like to Pot the whole pickup after assembly.
Tht gives the coils minimum potting, but quietens the whole overall pickup.
Please let us know what you come up with!
**If you have any ideas, please jump in?