Originally I noticed that the rear track width between the mustang and the focus was only about an inch different. Since track width is to the center of the contact patch this includes comparing different tire width and wheel back spacing.
I decided to measure the distance between the wheel mounting flanges to get a more objective comparison. I used some old metal stock to make a big caliper, then slid it off and measured the width on the original Focus suspension:
It was more straight forward to measure the mustang axle: 59.5". With the wheels on the axle, not quite fitting over the hub, they are out about .300 per side from seating against the brakes, so at 60.1 inches, they seem 2 inches narrower than stock, quite close to touching the inner wheel well:
So I have 3 options to get the wheel to fit over the hub:
1) Lathe the axle hub
I would only need to take about .010 off the diameter. This would mean removing the axles. I don't know if they would fit in my lathe. I am not wild about this option since this seems like I will end up too narrow
2) Grind out the inside of the wheel
Still concerned that the width will become too narrow for the wheels to clear the wheel well
3) Custom spacer
There are lots of ways this can be done. I think the easiest way is to buy a pair of aluminum spacers and press longer studs into the axle hub. This is cheaper than a wheel adapter, and saves me from the strength and vibration issues that come with that route.
The mustang studs are 1/2 -20 thread. The focus is M12-1.5. The mustang lugnuts do fit in the foocus wheels, so I don't HAVE to change them. It would be nice, so I looked at whether I can get any wheel studs that are long enough and will press into the flange. Just to make sure of the knurl diameter, I knocked one out and measured it:
.615 dia.
Nothing in M12 is even close to that big, so for now I will order long mustang studs. In the future, if I have the differential apart, I can remove the axles and have new smaller holes drilled 45° from the current ones. I don't want to do it by hand now, because with 3 inch long wheel studs and no hub to center the wheel, I will need them to be really straight, and in exactly the right spot.
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