I have a quick question for anyone who has changed to extended wheel studs.
Can anyone tell me how much you can increase the knurl diameter (beyond the stock 14.2mm) before it becomes too difficult to press/pull the studs into the hub without any drilling or filing? Maybe the answer is '0', I don't know, hence the question.
I'm considering Dorman 610-445 studs, which have a knurl diameter of 14.48mm. I really don't want to have to drill or file anything if I can possibly avoid it.

Silly question but can you just buy the extended SW20 studs from ARP?
 
Ahh just read that the ARPs are 25mm or so longer than stock. Nevermind.

Yeah the ARPs are too long, they are for people using big spacers, not 3-5mm ones like me.

2hardtop mentions in this thread that Supra studs are 2mm longer and Landcruiser are 6-7mm longer.
http://www.mr2australia.com/pop_printer_friendly.asp?ARCHIVE=true&TOPIC_ID=15381

if its any help, im running the std wheel Nuts with a 5mm hub centric spacer. you can go upto 5mm on a std nut but any more and its advisable to change, obviously your running more power than me so somethign to take into consideration..

I have standard wheel studs at the front and only a 3mm spacer at the moment, and it only takes about 3 turns to tighten the lug nuts! My Work Equip Anhelos rims must use up a few more mm of the studs, compared to other wheels. Maybe my bigger brake rotors are also thicker than stock, where they mount to the hub.

Anyway, let's get back to my original question:
How much you can increase the knurl diameter (beyond the stock 14.2mm) before it becomes too difficult to press/pull the studs into the hub without any drilling or filing? I'm considering Dorman 610-445 studs, which have a knurl diameter of 14.48mm.

I've got no idea how much wider you can go. Any reason you can't use the Landcruiser studs?

I couldn't find any specific or definitive description about the Landcruiser stud dimensions. Maybe someone else will have more luck.

At 14.48 I doubt it will pull in easily.  Most if not all aftermarket studs are too thick in diam. in the "knurled" section but also too long ( measured longitudinaly)in the "knurled"area.  I have overcome this problem in the past by very carefully grinding off some of this extra length.  Just brush on a fine bench grinder as you roll the stud in your fingers.  Takes time.  Softly Softly.   Also please do NOT knock the old studs out or the new ones in by hitting as most apes do as this will impact directly on the wheel bearing. Make up a puller.   I never use an actual wheel lug nut when pulling in new studs.  I use a ferule washer and good ordinary nut with grease.    Wheel stud breakages mostly caused by over tightening.  These only reqire 76 lb ft in service so dont go too hard on em installing.   PM me if you want my phone number.   Cheers.