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Hi, "redrill the hubs"
therein lies the problem. A 4x98 PCD Fiat/Lancia hub cannot be redrilled to 5 stud - any 4 to 5 stud won't work unless they are the same PCD, allowing one hole/stud to be used in the new configuration - e.g. 4x108 to 5x108. So even if there is enough diameter in the hub itself, which is doubtful, the geometry just doesn't allow it. 5mm wider radius isn't even the width of the hole/stud. Draw it on paper and you'll see what I mean. Maybe an Alfa 166 hub and shafts could be adapted for the rear (same as Dino wheel). A Fiat Dino or Fiat 2300 hub could be fitted on the front easily.
what if you re-fill the previous holes and then make the new ones in 108 mm pcd?...is that impossible?...someone has told me it´s possible, but maybe expensive...you could also use a 5 stud hub from another car, but retaining your hub-carriers/uprights....
Hi, I guess welding up the 4 stud holes then redrilling in 5 stud configuration is an option if it doesn't affect strength, balance and there is enough diameter in the hub face. Do take a look at the back of the hub face too - most modern ones have thick and thin parts to get lowest possible weight. You wouldn't want a stud in a part that was thin!
Swapping the whole hub is an option and relatively easy when the hub doesn't include a splined hole for the drive shafts. Here is a link to photos and description of how someone put a bigger 5 stud hub from a Mazda RX7 in place of a smaller 4 stud hub on a Mazda MX5 (Miata). This was on the front so no drive shafts involved.
As far as I know the Alfa 166 has the same PCD and centre bore as a Dino wheel. (Same company after all!) Dino wheels were the same on Fiat Dino and "Ferrari" Dino 246 GTs. Of course the Alfa 166 is a front wheel drive car so maybe it's rear hub could go on the front of a Deon with a little modification. I guess a front one with drive shafts could be adapted to the rear.
Failing this you might have more luck by contacting Gerry Hawkridge of Hawk cars. He makes Stratos replicas (which originally had the Lancia Beta bits that the Deon used) He makes 5 stud conversion kits - in 5x98 and , I think, 5 x 108. He also used to make Dino replica parts.
[email]enquiries@hawkcars.co.uk[/email] (5 stud kit is about GBP527+VAT)
Hi, I found some pictures of a project where someone changed stud numbers and PCD by welding and redrilling. In this case it was turning a Mazda RX7 five stud hub to a 4 stud Mazda MX5. It involved welding up the holes and the irregularities on the RX7 hub (they aren't circular - in order to save weight). New holes were drilled and the whole lot turned on a lathe: