Brake rotors

If the problem is only 1/8", you could easily file out the required clearance from the center 'face' of the caliper between the plates. In fact, you probably wouldn't have to cut that much to get the required clearance between the edge of the rotor and the inside of the caliper. Depending on how the caliper is hitting the rotor, it could actually be VERY little metal to get the clearance you'd need.
The metal in the caliper is a lot softer than the rotor, so the machining work would be a lot less technically challenging and you could be very targetted if you wanted to be minimalist.
I wouldn't do it, but the idea isn't terrible.

steell wrote:

Kidkawie wrote: cut the caliper. (Flame Retardent- ON)

I can't see how that would work.
Care to elaborate ?

Grind out the caliper where the rotor hits. You have a single piston caliper, right? No fluid on both sides. 1/8" should be fine.

Sorry for the missing posts guys. No time as school has been kicking my arse!! The caliber clearance is in diameter not off-set so grinding on it is not looking like an option. Just walked out in the garage to check and if you are right Kid then this might be a cheap swap. Hope to do an update in my build thread. Pictures are key in this journey.

Kid is right!! Can I grind 3/16 out of the caliber and still be safe??? gonna break the caliber down and check clearances in the morning.

just to update the thread............Took the caliber apart and hit it with the grinder. Centered the wheel in the forks and made some changes to a caliber mounting bolt and its on the bike,
!976 kz400 with 09 ninja 250 front wheel/ tire
Still gotta run brake lines, master cylinder, and still put the grinder to the rotor just for a bit more clearance.