lot more than 1/4" too big, the hole shouldn't be much more than the diameter of the inside of that nut, just enough to fit the stud, and over-torquing should stretch the stud, not drill out the hole, that wheel was probably bad when you got it from being run with loose lugnuts .... hopefully you're not meaning to run one 15" wheel and keep the other 16"

Bill

Moved over to the Passing Lane

"When we tug a single thing in nature, we find it attached to the rest of the world" ~ John Muir
"When we tug a single thing on an old truck, we find it falls off" ~ me
Some TF series details & TF heater pics