I put a set of 2010 18in Sahara rims and tires on my 05 TJ. I was looking for a thread on it and could not find one, so i figured i would take some pics and post it. The bolt spacing is different, as most people know, and also tire size is 32.2. I didnt want to spend the money on a new tire carrier or a bumper mounted carrier. Total cost was $48 after buying one adapter and 3 stock front wheel studs. Maybe another $15 if you had to go buy the extra items. I used some hardware, rubber mudflap that I cut to extend the rubber tailgate rubber stops and some 1in PVC pipe I had laying around to extend the brake light, and a Can of chassis flat paint for touch up. I've read on here you can go up to 33in tires with the stock carrier... I don't think it's that much heavier then a rubicon tire that came on TJ's.
1) Cut off old wheel studs on carrier flush and grind flat
2) Drill 1/2 holes 1 1/2in or so above the old wheel stud locations.... You cant go too high.. I also widened the holes a little.
3) Grind the spurs and bevel the new studs so the can be pulled into the hole. Sort of the same when you change any stud.. Its Almost like its pressed in. Mine were close to the back of the old stud....so I flattened one side of the stud so when it is pulled into the hole... It won't spin... You can see in the picture.
4) Use a lug and a bigger nut so you can tighten the stud and pull it in flush.
5) Then I mounted my adapter.
6) I cut 4 pieces of the PVC pipe...about 3 in long to raise the brake light. You can make it higher if needed...I used 4 4in bolts.
7) The bottom bumper hit the tire fine... The right and left needed to be moved out about an inch... All tires are different.. So measure. I cut 4 pieces of mudflap and got 2 longer bolts to attach it into the same hole. Don't over tighten... It will strip. The will be held in place with the tire anyway so it doesn't need to be supper tight.
At the end my tire was about 3/4in from the top of the bumper and it seems strong. The good thing is if I take the tires off and go back to the stock tires it will still fit the carrier.