Clunk in front end

[Divorce Court Dan]

My buddy has a 2000 Echo. I recently changed the front hub bearings, rotors, pads and sway bar links. After doing so, something in the front end bangs when the brakes are first applied in forward or reverse. The only reasonable explanation I could find was the wheel stud holes on the rotor are much larger than the studs themselves and therefore appear to be slapping back and forth on the studs. The rim has shiny spots from rubbing back and forth on the rotor. The problem is the holes in the rotor are all supposed to be that size. Even tried the dealer. My buddy is also complaing of a tingling noise in the front end. Almost sounds to me like the sway bar links, but those are new. Any ideas? I'm stumped on this one. And of course he is not too happy because his car did not have this condition before. Thanks