Mastrcruse, my sincere apologies for your issue. We will followup with you on Monday morning. I'm sure having this happen on the weekend left you feeling a bit stranded, and so I wanted to get in here and provide as much information as possible today. I cant see your order number and I don't have access to the serial number log at home. Can you tell me whether you have our new aluminum knuckles or our Pro60 knuckle?
There are 2 possible reasons for what you are seeing. It is possible, but unlikely, you received an 8on170 hub. It is possible that the hub is machined incorrectly, but also unlikely.
The studs locate on a knurled diameter. The knurl allows the stud freedom to move as it is pressed into place. This could allow the studs to splay slightly outward, which may be your situation. The longer studs we use can tend to magnify the problem making the tips of the stud more off center than a shorter stud. Normally the holes in the wheels are big enough so it is not noticeable during installation, and the lug nuts conical seat squares and sets the stud on the first installation when tightened. This is why re-torquing is so important whenever wheel are changed.
The press tool we have may be worn. We have had to replace it in the past. Knowing which knuckle you have or your order number, will allow me to zero in the tooling we used for your build.
After looking at your photo, if you are in a hurry, aTX427 suggestion is valid and harmless if you don't get carried away. Light taps with a dead blow on a lug nut at the tip of the stud will likely make installing the wheel easier. If the wheel does go on, torque the lug nuts by hand to about 50 lb-ft. Then see if the wheel slides over the studs as you originally expected. Don't gun the lug nuts down all at once. Work in a circular pattern gradually working up to higher torque values. If that looks good go ahead and full torque. Re-torque after 100 miles and again at 300.
Lets connect on Monday to make sure you are good to go.
