So I had all four wheels off to redo all new pads, calipers, hoses, and brake cables as well as a brake flush and a tire rotation.

Car has been on jack stands the entire time for 3 weeks since I dont have any freetime.

HERE IS WHAT HAPPENED:
Went to go put the rims that were on the rear to the front. They went on just fine.

Went to go put the rims that were on the front, to the back, and they dont fit on the back now.

Soooo...I scratched my head and put them back in their original spots and all was fine.

I then thought it was a fluke and put them back on, and they are flush on 1/2 of the rim to the caliper, and like 1/8" off on the other 1/2 so I tried flattening them out by tightening the lug nuts and damn near stripped a lug nut out.



What the hell is going on and how do I fix it?

 

What wheels do you have. Also, make sure you got everything right and your wheel is not hitting against the brake caliper.

 

If you have late model wheels on it, the ones on the front were probably never relieved on the back side to clear the rear hubs so they could be rotated.

http://shbox.com/1/4th_gen_tech2.html#wheel_mod

 

Man, I feel stoopid. I have read and read and read about that happening to people but I never thought it would happen to me.

Shoebox, thanks for the insight and I appreciate you reminding me of your page/where the info was.

GreasyB, I appreciate the help even though it wasn't the solution to my problem.

I'm still shaking my head as a I get ready to fire up the die grinder.

 

There's also a writeup on the problem in the FAQ on the Wheels and Tires forum.