trying to fix slightly ovalled lug holes

I bought a set of these honda alloys and did not notice until I had them refinished and painted that one wheel was driven with loose lug nuts resulting in a slight ovalling of the lug nut seats.

Honda uses a pressed steel insert and a ball seat that is impossible to find. Honda doesn't even list them in their fiche, there are few specialty companies that sell them but nothing that fits without going oversize/machine shop.

I spent the weekend at the junkyard, very few single alloy wheels laying around which makes sense as a clean set is immediately sold.

So here I am trying to fix this rare as hen's teeth lug seat and looking for suggestions.

I'm contemplating these options:

-Clock all the oval/flattened seats pointing towards the outside of the rim and try mounting the wheel. The idea is even if the wheel rotates slightly in the hub centric location it should still encounter enough "shoulder" to stay torqued.

-weld a bead to build up the flattened seat. Shape it best I can with a die grinder. then cut a couple slots into a lug nut, try to use it as a milling bit to cut the ball seat shape back in. I have some doubts how effective this would be since it's hardened steel vs lug nut.

-drill the nuts and safety wire them.

Any suggestions? Pictured is the ovalled insert on top and one I knocked out from a junkyard wheel but is the wrong size.

 

@twowheeled

More likely thread will Need to be move to Off Topic ,
Does the wheel have a Register , if so
Lug just clamps wheel ,
Wheel could be tig , then deg of cone angled in @ home ,
Or cut that lug , take tapper off ,then maybe cut wheel tapper out just enough to have a flat mount pocket .

Have you seen these ,
Also these stlye of hole cutter's can be used in a drill press with care & thought
With out a trip to Machine Shop,
& a web site about lug repair and understanding

https://www.race-dezert.com/forum/threads/lug-nuts-lets-talk-lug-nuts.141107/

 

Cut down the flat spot on the wheel so the cone grabs first.

 

make new inserts using your lathe.

If you don't have a lathe, this is a great excuse to get one.

 

I'd see if you can find an insert that has the correct inside diameter but is too large on its OD. Then have someone with a lathe cut the outside diameter to fit the enlarged but slightly egg shaped hole. Then mount the insert on a stud inserted in a drill and use some lapping compound to seat it better. Maybe make a couple extras to use for the lapping. Might get you where you want to be.

Depending on the angle and size of the chamfer, you might find a cheap grinding stone on a shaft that could be used to round the egg shaped holes.

OR...........you could see if you can locate some counterbore tools cheaply (?) on Ebay or Facebook and take the seat in the wheel slightly deeper. They are expensive but there are some decent sets made by Shars and Accusize that are available for $100-$130. Check to see if they have sizes you can use. Resell them when you are done.