cory2081 wrote:If he does it that way, he may damage his wheel. Just use an impact or a long cheater bar and turn it til it breaks. you know it's bad anyway and you need to replace it. This is quick and easy and will not damage anything other than the stud. I seriously doubt that the splines on the stud are messed up and it is turning in the hub, but, that is very easy to check. Make sure that is not happening before using this method!
If the problem turns out to be the stud splines having given way, then a breaker bar or impact wrench will not work as it will only spin the stud and the nut.
I think a variation of IvoryJ30t's recommendation may work even if the stud is spinning in place. Start with the center punch aas he already described. Then starting with a small drill bit drill a hole. Get drill bits that are long enough to drill fairly deep with the wheels on as you want to be able to drill all the way to the lugnut seat of the wheel but not get the drill close enough to the wheel to scratch it. Progressively use larger bits. Use an adjacent hole as a reference as you really only need to drill as deep as the lugnut seat itself. Eventually, you will have drilled out the entire stud and the lug nut will simply have nothing to hold onto. Couple of important things to note. Be as accurate with the center punch as possible. This will help avoid having to drill a larger hole in order to get the entire stud. Secondly, make sure the drill goes straight into the stud. If you are a little off, you will end up missing the base of the stud and perhaps drilling your wheel. your pilot hole with the smallest drill bit will set the pace. The rest of the drilling after that will be much easier to control. If you get the hole drilled straight, you will have little to wrry about if you drill too deeply. Most holes in the wheels at it's narrowest point still have a small tolerance between the hole and the stud itself. The stud should be drilled out before the drill can actually make contact with the wheel if the hole is centered and straight in. Lastly, keep at least 2 other lugnuts on the wheel (doesn't need to be too tight) just to keep the wheel from falling off while drilling potentially damaging the wheel or causing injury to you.
This might end up being a lot harder than it sounds. You might even take the progressive drilling just to the closed end of the lugnut first to open it up and make sure you are centered well on the stud itself.
If you end up messing up on the pilot hole, let me know. I have another idea that can definitely work so long as your wheel can accomodate it and you can find a couple of very specific tools.
The only potential problem I see with drilling would be if the stud is loose enough that the stud will spin with the drill. How loose is it by the way?