Is there any real problem with installing wheels in a frame, when the axle over-locknut width is slightly greater than the dropout/fork blade spacing (approx 5 mm or less off, and prying the dropouts/ fork blades apart enough to install the wheel isn't particularly difficult. I ask because i am trying to do a cheap rebuild on an apollo sport 5, and the original steel wheels are (A) steel wheels and (B) have some very ugly rusty spokes, and refurbishing them (new spokes) doesnt seem time/cost effective to me when i have some perfectly good, low end, aluminum wheels that just don't quite fit. For the record, I have done this before, with no problems (for me) other than minor pain in the ass wheel changes. I was just wondering if anybody has any good reasons not to go this route.

also, if i go with the aluminum wheels, they have a seven speed freehub (shimano) opposed to the 5 speed suntour freewheel on the original wheels. probably for the best if i opt to replace the chain as well, right? Lastly, the derailleur is suntour honor, am i likely to run into issues shifting that over a seven speed shimano casette? obviously its not ideal...but in a friction application I can't see it being a big problem unless it doesn't have the range to cover the wider cassette.

I think that about covers it for now, i think all the relevant info is there, any feedback you have is appreciated.