Hi Adam
Sorry to hear the Vitesse wheels are not co-operating.
Easy one first. For the nuts I'd start by running a tap down them, on the principle that more thread engagement is better than less where wheel nuts are concerned. If that doesn't fix it, only then get the grinder to the studs.
Even with 3mm skimmed wheels, Lucky still had problems with the drivers side D post. I put a hydraulic bottle jack between the inner mud guard and the D post and pumped until I ran out of bottle (
- courage, that is). This moves the bottom fixing for the wing out a tad, and the bottom of the wing with it. But that was easily fixed by a gentle lean on the wing, as no doubt, Rover themselves did on the line! Then of course you could try getting the backs of the wheels skimmed. Do all four - you don't want to get left with a wheel that only goes in one location! Shouldn't be that pricey - take them to a local wheel refurbisher as they have lathes already set up to take wheels. And while your at it get them to reseal the inside of the wheel and the tyre bead so that you don't subsequently get problems with the tyres slowly going down. Beyond this there are a couple more avenues to try. You could try moving the diff across a bit by releasing the lock nuts on the panhard rod and lengthening the rod slightly. Don't overdo it as there is the potential to put a permanent strain on the diff mounting bushes, which can't be a good thing. Next up is to remove the inner skin of the D post. The area that matters is double skinned for no obvious reason (introduce a water trap so we can all get practice at renewing the D post?). Simply angle grind off the inner skin in the affected area, smooth out the outer skin and reweld the inner skin back to the outer rather higher up.
Hope that helps.
Chris