Hi Todd,
Your wheels look absolutely amazing and serve as a huge motivation for my little endeavor. I need to order my custom lips and barrels by next week and I'm trying to piece all of this together. I had a few questions about your setup so I figured I would post them here if you don't mind. It's late and this probably reads like a high school math problem at the moment. I'll revisit in the morning. The good thing about this is that I know that our faces will be the same dimensions, and that you can fit 3.5" lips in the rear, and 2.5" up front. I'm starting only with a wheel face, so now I have a reference point to work with.
Just to confirm - you only modified your rears correct? It's a bit hard to tell in the pic, but I assume that you couldn't squeeze 3.5" lips under the front fender. I didn't realize that I could fit 3.5's in the rear until I revisited your thread. This puts a smile on my face.
As far as offset, I was wondering if you saw ET11 stamped on the wheel or if you calculated this. You mentioned that the barrel was 4.5" wide from the weld to the tire bead seat, which is the proper way to measure the width. So I figure the barrel is actually closer to 5" wide in total. Did you do the same for the 2.5" lip?
I built this little offset calculator in Excel for my WEDS, and I'm calculating your a 7" wheel with a 4.5" barrel at zero offset. That's 4.5" + 2.5" = 7". The face mounts at 4.5", and the flange is 1" back from that at 3.5", which is also the centerline of the wheel (aka ET0). Now if you factor in the thickness of the original WEDS lip, it could be around ET4 - ET6 or so. For those reading who are unfamiliar with WEDS, the assembly pattern is barrel + lip + face. The faces sit on the lips, they are not sandwiched between the lip and the barrel. The 4mm that I'm referencing is the thickness of the aluminum used on the lip.
The move to a 3.5" lip actually sets the offset to -12.7mm in the rear according to my calcs. Again, I'm not factoring in the gauge of metal (likely .190") of the new lip in this equation, which adds about 4mm to the offset.
Screenshot of my calculator. Note that the image that my calculator generates does't actually display the extra .5" outside of the bead seat, but it doesn't matter for the calculation.