Wheel spacers 1 - 1.5" questions

Not sure I agree with your theory on studs. If the spacers / wheels are properly tightened, the sheer force is the short area between the hub and the spacer, and the spacer and the wheel.

Seems like a good idea to have a centering pilot at least on the hub side. A little work with a lathe would take care of that.

Rice, scare up a friend with a lathe and some aluminum, and MAKE 'em