Hey bucky, sorry to hear you're having a time of it. With something that should just sort of "bolt-n-go" relatively speaking.
I don't remember seeing studs like yours on a Bronco before. But yours certainly looks like an original axle. Just looking at it's apparent age.
But all of the ones I've worked on had a shank that tapered and just barely protruded through the axle flange.
Nothing near as proud of the flange as yours. And I see what looks to be two different types as well? If so, then some of them seem to have already been replaced.
But they sure do look just like the image in 1969Miller's post, of stock replacement parts.
I agree with the others that mentioned forgetting the aluminum spacer. Wrong direction to take to the solution.
And while I generally agree that it's better to change the studs than to modify the rotor, because it'll mean you have to do that every time you get a new rotor (but how often is that really going to happen?), I would not even hesitate to drill out the holes in your current rotor so you can finish the project quickly and get it back on the road. Then keep looking for the correct studs at your convenience.
But if you have the time to spend on hunting down the parts, and it seems like there are some good candidates listed already, then it's the right way to go I think. Getting the studs that will accommodate the rotor.
If you can only find some that still stick out too far, I would at least get the ones that have the taper, rather than the hard shoulder. That way you might not have to open the holes as much. Or you can taper/bevel the side of the rotor that faces the flange, and get it to all play nice together that way.
Heck, even on non-Broncos, I've had to bevel holes in stock replacement rotors that were going on vehicles with all original hardware still!
Good luck.
Paul
