Well, Here's what I am going with for my solution to this. I think it should work well. I have fitted up one for test purposes and would say that it is just about as good and tight as possible, without re-sizing the lug holes to accept the more available/modern lugnuts.
I ordered some stainless steel washers through McMastercarr. They are a little on the thin side so I doubled them up. With a little effort they pressed tightly onto the lugnuts which gives the lugnut the most surface to grab. They are also slightly larger on the outer diameter. Any larger would not fit. They torque down nicely. After doing the first one, I decided to hone out the inside diameter of the washers just a very small amount, so it doesn't take as much force to press them onto the lugnuts. But they still fit on the lugnuts very firmly and stay in place.
I'm gonna call it good to go and keep a close eye on them once I get the car back on the road. I think it's reasonably good solution. I single, thicker washer would obviously be better! I do have some samples coming from another company and we'll see how those pan out.
2 packs of washers and shipping came to about $28.00
View attachment 1715273648
View attachment 1715273641 View attachment 1715273642
You can see how nice and tight the fit is. Critical with the super-small hex head surface on these!
View attachment 1715273643
Here's a comparison of the old crushed one and the new stainless ones:
View attachment 1715273644
Here's how the new washers seat in the wheels.
View attachment 1715273645 View attachment 1715273646
Here's a pic of one of the old washers to show the size difference:
View attachment 1715273647
