Another thought: how confident are you there's no physical issue with the spacers from a mfg defect? You could pull them off and measure all around them with a caliper to confirm uniform thickness. Or just try driving the exact same setup but with the spacers removed (assuming your wheels don't rub that way). There should be headroom in the lugs if you went to extended studs, probably.
In a similar vein (and sorry if I'm going over stuff you already know!): be sure the mating surfaces of everything involved are clean of dirt and rust buildup. The front face of the hub flange, both sides of the spacer, and the inside face of the wheel center. Use sandpaper or something similarly aggressive to clear out the rust, and then make sure it's cleaned after that to get sand particles off.
Last edited by wstar; 03-21-2014 at 12:24 PM.
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