Long story short, a car I just bought has 25mm spacers with extended lugs and one of the nuts on the original stud was rounded. I tried to take it off a few different ways and ended up completely rounding it using an air impact. It may be cross threaded, but the threads that are visible don't look that shiny. I was thinking of welding a deep socket onto the end of the nut if I can get the mig torch in there. If I need more room maybe cutting through the spacer on the side with a plasma cutter could work. Any other ideas?

Eventually I'll put longer wheel studs (probably 12x1.5 instead of the stock 12x1.25) and new bearings/grease in, but for now I'd like to not destroy the stud.

 

Welding sounds like the quickest way. Do you have a Dremel/similar unit, and a lot of time? Grind that ****** off if so. Or grind some flat sides onto it and try a smaller socket, but those would probably round off as well if it's really jammed on.

 

Cut the wheel, like this guy:

So, Dont buy a VW - Honda-Tech

 

Seriously, read that and don't make his mistakes.

 

I wasn't able to get anything reasonable inside the spacer to turn the nut so I made room. Good thing the thing is (was) aluminum. Fortunately, I don't plan on reusing the spacer. Liquid wrench helped. I couldn't get any weld penetration on the rounded nut so I gave up on trying to weld something to it.

 

Faeflora, is that you?

 

I am glad I wasnt the only one


Why didnt you just drill into it the lug just a half size smaller than the threads?

 

That's a lot of trouble to go through all because a PO doesn't comprehend how to torque a bolt.

 

Available locally and online $7-$40

 

and available for free in your local wheel thief's pocket.

 

Tried an extractor. Didn't work without cutting the spacer because it wouldn't fit. Drilling/cutting that lug wasn't an option.