@UROpartsman @djway I do not find your solution to be a correct or sound. The rotor locates and centers on the OD of the hub. reducing the OD can cause the rotor to be off center and vibrate.
Nor do I believe that oversize studs will cause distortion in a properly made hub.
I have installed dozens of studs of various brands and have never seen one distort. The stud splines will get shaved down if the fit it too tight. See attached pictures.
I have installed the studs in converted rear hubs which have less material than the OEM hubs and your reproductions.
My belief if that the material you are using is not as strong as the OEM material.
Care to share the Rockwell hardness, alloy used and yield strength of OEM to your material?
1. If the material is giving when a stud is install how is it going to hold up under high axial load?
2. Any testing to show the strength of your hubs vs OEM or Dansk?
Does this problem affect the 911 hubs also?
3. Which rotors are the hubs made to accept? The 914 rotors have a different pattern for the two holes for 6mm the attaching screws. The 914-6 rotors are mm larger in OD and can hit the stock 914 caliper web. If you drilled both patterns either rotor could be used.
4. Here is a product improvement idea. Make the 914 rotors with the centering feature as used in 1974 and later 911 rear hubs. It is a known problem that the lug centric OEM hubs can cause wheel vibration. Those are the desired hubs for a 914 conversion but require a spacer on the shaft to locate the hub correctly due to the taller bearing used with those hubs.
I as looking forward to getting a set of these hubs but your approach to fixing a problem is scary.
@superhawk996 Your input is welcome.
@914sixer