Jay’s Build: Custom Forged Spacers for Range-Rover Sport LW

Written by the workshop team at Crumpsall Alloys — Manchester’s forged wheel specialists.

The car that arrived…

Jay rolled into the workshop with his 2019 Land Rover Range-Rover Sport LW, and the mission was clear from the moment he parked up. He wasn’t looking for a complete overhaul or a new set of Land Rover alloys; he simply wanted to fix a visual imbalance. His brother had recently fitted 25mm spacers all around on a similar setup, and Jay wanted that same aggressive, flush look where the wheel face sits tight against the fender edge.

The car was already sitting well, but the wheels looked a bit too tucked into the arches, especially given the muscular lines of the LW generation. It’s a common issue with modern factory setups; manufacturers often prioritise maximum clearance for suspension travel over pure aesthetics. Jay had seen the result on his brother’s car and was convinced that a uniform 25mm spacer application was the way to go. However, as anyone who has spent time in a workshop knows, what looks good on one vehicle doesn’t always translate perfectly to another without a bit of technical scrutiny.

Diagnosing the job

When we got the vehicle up on the lift, we didn’t just take Jay’s word for it. We started by measuring the actual clearance between the current wheel edge and the archline. It was immediately obvious that the rear setup was behaving differently than the front. While the front wheels had a bit of room to grow, the rear arches were much more sensitive to width changes. If we had simply slapped 25mm spacers on the rear as well, we risked a bit of scrubbing during heavy cornering or when the car was fully loaded.

We went deep into the technicals, verifying the 5×120 PCD and the critical 72.6mm centre bore to ensure any custom work would be dead-on. Precision is everything here; even a fraction of a millimetre deviation in the hub bore can lead to wheel vibration at motorway speeds. We also checked the existing lug nut configuration, confirming the M14x1.5 thread was healthy. We also had to be careful with the diameter considerations—while the LW supports a massive range from 19″ up to 24″, the way the width interacts with the arch is what matters here. There was no room for guesswork, which is why our fitment AI is such a vital part of our process—it eliminates the risk of ordering a thickness that simply won’t clear.

The decision: Forged Wheel Spacers

After measuring the gap, we made a professional call: a split setup. We decided to stick with the 25mm thickness for the front to keep things consistent with the driver’s side feel, but we proposed a custom-engineered solution for the rear. To get that perfect, symmetrical flushness, the rear needed more punch. We decided to move to 33mm Forged Wheel Spacers for the rear axle.

Choosing a forged product wasn’t just about thickness; it was about structural integrity. When you’re pushing a wheel out by 33mm, you’re increasing the leverage applied to the hub. Cheap, cast spacers can be prone to cracking under the heavy load of a Range-Rover Sport. By using high-grade forged aluminium, we could ensure the spacers were incredibly strong yet lightweight enough to avoid unnecessary unsprung mass. We also had to ensure the width compatibility was spot on, considering the LW can run anywhere from 7.5J up to 11J widths. Every single dimension, from the 72.6mm bore to the outer diameter, had to be perfect. As always, our automated system at checkout handles all these complex width and diameter calculations for the customer, so there’s no need to worry about the maths.

The work in the bay

This wasn’t a job where we could just pull something off a shelf. Because of that 33mm requirement for the rear, we had to go into production mode. The workshop team had to oversee the precision machining of these spacers to ensure they were turned to the exact specifications. We use high-grade CNC lathes to ensure the 5×120 bolt pattern is perfectly concentric. It’s a painstaking process—one slip of the tool and the part is scrap. We had to ensure the mating surface was dead-flat to prevent any movement between the hub and the wheel.

The machining and turning process was intense but rewarding. We were monitoring the tolerances on the 72.6mm bore constantly. We also had to ensure the new spacers could accept the existing M14x1.5 hardware securely. It’s a proper job that requires patience; you can’t rush the heat treatment or the final finishing if you want them to last. The whole process, from the first measurement to the final polishing, was completed and turned around in less than two weeks.

The result

The moment we fitted the final 33mm rear spacer and torqued the nuts to the correct 140 Nm, the transformation was undeniable. We dropped the car, spun the wheels, and checked the clearance under full compression. It was bang on. The wheels now align perfectly with the archline of the vehicle, creating a much more aggressive, planted aesthetic that the factory setup was lacking. The rear stance is pushed out just enough to bridge the gap between the tyre tread and the fender edge, making the whole car look wider and more muscular.

The real victory, however, was the speed of delivery and the precision of the fit. We achieved a 100% perfect archline alignment in just 12 days. Jay was absolutely delighted when he saw the car; the way the light hits the edge of the wheel now, perfectly flush with the bodywork, is exactly what he was after. There was no scrubbing, no rubbing, and no vibration—just a clean, professional, and much more imposing presence on the road. For anyone interested in the technical side of fitment, you can check out our wheel offset guide to see how spacing affects your car’s footprint.

Could we do the same for your car?

If you’ve been looking at your wheels and thinking they look a bit too tucked into the arches, we can help. Whether you need standard spacers or something completely bespoke like Jay’s 33mm rears, the team at Crumpsall Alloys is equipped to handle it. You don’t need to know your PCD, your hub bore, or your exact width requirements. Simply head to manchesteralloys.com and use the selector for your Land Rover Range-Rover Sport LW. Our fitment AI will automatically identify the correct specifications for your exact trim, ensuring that what you order fits the first time, every time.

Frequently Asked Questions

How much does custom forged wheel spacer work typically cost?

Prices vary depending on the thickness and whether they are standard or bespoke. A set of high-quality forged spacers can range from £150 to £400 depending on the complexity of the machining required for your specific vehicle.

Will these spacers work on my older Land Rover model?

Not necessarily. Older models often use a different PCD, such as 5×130, so 5×120 spacers won’t fit. You must use our fitment AI to verify the specific bolt pattern and hub bore for your exact year and model.

How long does the custom machining process take?

For bespoke items like Jay’s 33mm spacers, we aim to complete the process in under two weeks. This includes the initial design, CNC machining, quality testing, and final finishing to ensure the highest possible standard of fitment.

Can I use my existing M14x1.5 lug nuts with spacers?

Yes, provided the spacer thickness allows for enough thread engagement. However, with thicker spacers, we often recommend longer bolts to ensure the nut can grip the stud sufficiently to reach the 140 Nm torque requirement safely.

Where do I start if my car has the same issue with tucked wheels?

Start by visiting manchesteralloys.com. Use our automated tool to enter your vehicle details. Our system will handle all the technical measurements, ensuring you get the correct width and offset to achieve a flush, professional look.

Reviewed by

Casey Jones

Forged wheel and performance car specialist · 6 years hands-on

First-in-the-world fitments on the new-shape Alfa Romeo Giulia Quadrifoglio, BMW XM, and Citroen Ami. Thousands of wheels and tyres personally sold and physically fitted across performance, luxury, and classic vehicles. Every article on this site is reviewed against real workshop experience.