1. Aizen, Gin, and Tousen arrived in Hueco Mundo to visit Barragan, wearing traditional Captain Haori, and Aizen had his glasses and old hair too. This means that this did not happen after he left Soul Society at the end of the SS arc, but before that, while he was still a Captain.
2. The maximum limit of the timespan that this could have happened in is 40 years, because Gin only became a Captain 40 years ago. So it coudn't have happened earlier. This in obvious from Rukia's flashback about Gin, where he states that Byakuya nii-sama and Gin became Captains at the same time, near after she was adopted into the Kuchiki House and graduated from the Academy. Rukia was adobpted into the Kuchiki house 40 years ago. This is obvious from the chapter in which Renji first visits her in her cell (before she was moved to the tower of solitude) and she says that in the sum of 40 years that she spent in the Kuchiki House, Byakuya never cared about her. Aizen visited Hueco Mundo somewhere between 40 years ago and before he left SS.
3. From Nnoitra's and Neliel's first meeting in Hueco Mundo, it turns out that Nnoitra hasn't seen Neliel in ages. This supports what we already established, that secretly Aizen had been in control in Hueco Mundo for years before the main storyline. Neliel and Nnoitra was sent out on missions to find Vastro Lorders. The ammount of Vastro Lordes that served in Aizen's army during the war... he found all those in the span of several years. Makes perfect sense in according to the lore of their rarity.
4. When Isshin defeats Grand Fisher, he states that it was different from the pre-Arrancar that he met 10 years ago. Urahara agrees, with this, quite probably placing the entire old team (Isshin, Ryuuken, Urahara, Yoruichi, Tessai) in the forementioned hidden arc.
5. The chapter of Gin's death. Aizen states that both he and Urahara came to the "Hogyouku solution", but neither of them could complete the damn thing. Aizen is shown feeding souls to the Hogyouku when he was still a mere officer and Gin was a kid. We do not know what Urahara did at this time, but Mayuri already knows him when he enters the Maggot's nest. My two cents on that at the same time in the past, Mayuri and Urahara created the Hogyouku together. Creating something that needs to be fed with souls fits Mayuri's area of science perfectly. He also disliked Urahara and said that he is an unplesant man. My other two cents on that Urahara stole the Hogyouku from him after it had been completed, and framed him for it, for which they put him in the Maggot's Nest, because creating something like that really fits the "effin dangerous" archetype. (If after all this somebody still sees Urahara as a good guy, oh wow dear denial.)
6. Turn Back The Pendulum. Aizen frames Urahara for the creation of the Vizards, to throw him back in the race for... whatever they wanted to achieve by creating the Hogyouku. I use "frame" very caringly, because Urahara actually did create the Vizards, by using the Hogyouku. His soul wanted to complete the experiment, and the Hogyouku granted it. Jet another good character quality. This could also be interpreted as a spit in the face from Aizen, "I know what you really are like". He fails to claim Urahara's Hogyouku for himself though, as Yoruichi frees him and Tessai, and he takes that with himself to the real world.
7. Aizen most likely sends out his Arrancars to claim to Hogyouku from Urahara. Isshin fights them. This is what most likely happened 10 years ago. In the final battle between him and somebody, Isshin loses his powers through Mugetsu. Aizen survives. Urahara secures the Hogyouku. Aizen failed yet again, but he's not giving it up so easily. Grand Fisher might have been involved in the fight, which he escapes from as the others battle, and kills Masaki, to at least achieve some collateral damage on the other side.
8. Aizen sends out Rukia to meet Kurosaki Ichigo, because he sees a possibility for a situation that which happened to happen. Sends out a hollow too to fuck them. Rukia acts entirely according to her psychological profile, and Ichigo gains power. Urahara also acts entirely according to his psychological profile and grabs the situation to display yet another good character quality and puts the Hogyouku into her to hide it. Plans to make her a human just so the damn thing could be forever sealed and not ever found again. Aizen is going through several different levels of trollfaces.
9. When Urahara realizes what the fuck is going on, Rukia is already back in SS. Taken back by Byakuya and Renji, who Aizen equipped with a reiatsu-detecting device specially designed to find Rukia regardless of Urahara's reiatsu-dampening gigai that he gave her. (Aizen outright states this in Deicide). Urahara sends Ichigo in to regain Rukia, knowing or not knowing that he's just sending in a second fish for Aizen to catch with the same bait. After the SS arc is over, Urahara and Yoruichi states that "we have started on the losing side". Yes.
10. Vizards arrive, Urahara and Isshin are not sure where they will stand. Makes sense because "there was no mistake, that was my greatest mistake". That is how Shinji quotes Urahara. It probably means that he acknowledged that they all became Vizards because he wanted that. And they probably didn't like him for it.
11. You know the rest.
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