well, it's about time to switch up to 5 lug, and since ITR suspension is out of the question i've decide to do a hub fill and redrill. as of today, i have the hubs out and have an ITR rotor to use as a template, tommorrow morning i'll fill the existing holes SMAW style. then anneal and grind flush, mark the holes and take them to a drill press. i'll update with pics as i progress.

note: since the inner splines on the bores in the hub will be too time consuming to cut by hand, i'll most likely tack the studs in place.

 

good idea

 

lets see some pics after.. never thought of that.. USDM 4 lug brakes on a 5 lug hub.

or.. why dont' you go out and buy 5 lug hubs? last time i checked it was about $100 a hub. and its true.. not guessing if the lugs are off balance, or un true.

 

see this makes no sense to me. I thought the whole point behind the 5 lug is for the bigger brakes and and the good lca now it sounds like you are doing this for looks.

 

I bought my 5 lug to get the bigger brakes

 

hey maybe he just wants to use different wheels, not ever modifiction needs to be for performace.

DIY

 

oh i agree nothin wrong with that!

 

let us see it when your done, and good luck

 

i'm really quite suprised at the positive responses. thanks for the support.
i didn't get to the hubs today, but i did some good practice fills, i had to learn a new electrode to do fill ins. not too hard though, it all comes down to being really acurate in marking and drilling the new holes,
the reason i'm doing the custom fab instead of buying the conversion is two fold,
first and formost, i'm broke. (lack of funds is the father of inovation)
second, i couldn't find a set of 15" 4x100 wheels as cheap as 5 lug, and i need wheels right away,
i've toyed with the idea before, but never had the hubs out when there was a good deal on 5 lug wheels, and when the hubs were out there were no deals.

 

It's too bad that you don't have a mill. (with digitals)


I could give you accurate x, y values for the holes.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by eLusive ek4 &raquo;</TD></TR><TR><TD CLASS="quote">I bought my 5 lug to get the bigger brakes</TD></TR></TABLE>

 

yeah soemthing like that would be great, my main concern right now is getting those holes lined up perfectly

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by thad &raquo;</TD></TR><TR><TD CLASS="quote">my main concern right now is getting those holes lined up perfectly</TD></TR></TABLE>

transfer punches ?

as long as you have a good template , its cake.

and BTW , I wouldnt worry about cutting splines , I run the GM extendedstuds in my car and I drilled out the OEM hubs to 1/2" no problem , pressed the studs in and good to go.

 

I don't think this is the best idea but I'm intrested to see how it comes out! I think if you took the 5 lug rotor or a hub to a machine shop and had them mill them, that would be the best and most accurate imo

 

until earier today i was having serious doubts, but i took a practice hub into the shop and started filling, i'm a bit more confident now, and i have a few more ideas,
heres the practice hub, the welds are really sloppy i know, i'm still getting used to this electrode, it melts off really slow, but heats the work alot, plus it freezes fast, i might try a different one just to see which is better.

the wheel stud holes (little ones) are really easy to fill, but the larger bores are jst so big that once they are about 1/4 filled, like half of the hub is glowing. my soulution is to weld a plug in them. i'll also need to press the bearings out of the rear hubs, so they don't get toasted.

 

I think mig may be a better choice. You should be welding peices of steel into thoes holes and not just trying to fill them up with weld.

 

the reason i want the extra lug is for the nice brakes, not the looks

 

i never knew that redrilling a hub would allow you to add bigger brakes. hmmm. i learn something new everyday

 

let this be the end all reason for fill/redrill 5lug: i'm a cheap bastard(broke to be exact) i'm doing this because i found 5 lug wheels for a better price than 4 lug. that's not the reason for the idae, but that's why i'm doing it now.
i'm arc welding it because that's what i'm familiar with and the materials are easily accessible to me, the lug bores are small enough to be easily filled with rod electrode, but the larger holes will be have steel plugs welded into them.
i won't be able to do anymore work till monday, but i'm looking forward to a stress free weekend i'll just work on the template till then.

 

Not sure if you have thouhgt about it or not but if you are heating the work piece that muhc you might wanna check it for warpage

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by rhyno &raquo;</TD></TR><TR><TD CLASS="quote">the reason i want the extra lug is for the nice brakes, not the looks</TD></TR></TABLE>

I dont get why everone is saying that is the reason they got 5 lug. You can upgrade your brakes for cheaper than a whole 5 lug conversion.

Yager-

 

Who cares what the guy is doing it for, brakes or looks.... Just Do it!

Some of you peeps are too practical ,sometimes you gotta do **** just for ***** sake. **** there would be no Moster Garage if we all thought like some of you.

 

as for warpage, i have considered it, and i don't plan to take any chances. after they are filled they will be surfaced, then drilled, then balanced.
as for the brakes, i'm totally with ImportHatch on this one, my oem brakes are good enough for now and when i upgrade it will not be a set of DC2S for $1500
i don't know of anyone who has done this before and i've got a bunc of people who want to see how it turns out. so i'll be the guinnea pig

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by rhyno &raquo;</TD></TR><TR><TD CLASS="quote">the reason i want the extra lug is for the nice brakes, not the looks</TD></TR></TABLE>

god, get off it... the guy wants to do something differant, and he's totaly broke, so this is a fun prodject to do.

he admits it... he has no plans to make the brakes stronger, he wants the extra lug nut for differant wheels.. so ******* what.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by eLUDEnu &raquo;</TD></TR><TR><TD CLASS="quote">see this makes no sense to me. I thought the whole point behind the 5 lug is for the bigger brakes and and the good lca now it sounds like you are doing this for looks.</TD></TR></TABLE>
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by eLusive ek4 &raquo;</TD></TR><TR><TD CLASS="quote">I bought my 5 lug to get the bigger brakes</TD></TR></TABLE>

5 lug with rear drums?

HA HA, wow I think I have seen everything now