Suppose that we're talking about $n\times n$ density operators, so that the rank will never exceed $n$. Now suppose that you choose $N$ to be much larger than $n$, and then arbitrarily pick a probability vector $(p_1,\ldots,p_N)$ and pure states $|\psi_1\rangle,\ldots,|\psi_N\rangle$. Assuming that more than $n$ of the entries in the probability vector are nonzero, and the vectors $|\psi_1\rangle,\ldots,|\psi_N\rangle$ represent distinct states, the decomposition
$$
\rho = \sum_{k=1}^N p_k |\psi_k\rangle \langle \psi_k |
$$
for the operator $\rho$ you have selected through this process will surely be different from the spectral decomposition of $\rho$.
Note that for a given $\rho$, it will always be possible to do something along these lines. If the rank of $\rho$ is 1, it will be trivial (meaning that every $|\psi_k\rangle \langle \psi_k |$ will have to be equal to $\rho$, assuming $p_k >0$), but as long as the rank of $\rho$ is at least 2, there will be a continuum of different inequivalent ways to do this.
In particular, for any choice of $\varepsilon > 0$ and $|\psi\rangle$ for which
$$
\rho - \varepsilon |\psi\rangle \langle \psi|
$$
is positive semidefinite, you could write
$$
\rho = \varepsilon |\psi\rangle \langle \psi| + (1-\varepsilon) \sigma
$$
for
$$
\sigma = \frac{\rho - \varepsilon |\psi\rangle \langle \psi|}{1-\varepsilon}
$$
and then recurse on $\sigma$. For any choice of $|\psi\rangle$ in the image of $\rho$, not just eigenvectors of $\rho$, this will be possible so long as $\varepsilon$ is small enough. And, as long you take $\varepsilon$ small enough each time, you could recurse as long as you like, and in general you will get different decompositions of $\rho$.