The caliper was fouling on the edge of the drive flange (much larger diameter than the Mini) and because the caliper body extends out past the flange itself it was going to hit the wheel centre. Note drawn in red drive flange.
Thanks for your help guys but I just don't like the idea of any kind of spacer. If I space the disc away from the drive flange, it runs off the machined bit which centralises it, and if I space it on the other side I am applying extra twisting force to those small screws (I was surprised how small they are too). As much as I like the brakes, I decided to look at other options. I initally thought I'd try a new disk with the Tarox caliper, but then figured I may as well try any caliper that would work and keep this kit complete to sell on. Anyone want a sexy set of brakes. Hardly used...
Back at that drawing board again, I tried to come up with a brake setup that required the minimum of machining, used stock parts, would work with the standard master cylinder and not have a limited pad selection. Opened it up to any caliper type, not just exotic ones, will be mainly day to day car so reliability and low maintenance probably rates over outright performance here. Oh, it also had to fit and not hit anything.
Soooo, after many hours of intesive web searching, DBA catalog reading and wrecking yard spannering.
Here is my solution. I hope it works.
1989 Hyundai Sonata discs (257mm) and 1991 Honda Civic calipers (49mm piston). Hopefully just need to machine down the 1100 drive flange to 140.7mm which will locate the disc (I had a go at this tonight on my lathe but these things are made of really hard stuff - will have to farm this out) and make up a hefty bracket to hold the caliper. This will add 10mm to the track but hopefully I can get away with it.
Some pics.
And Hallsey, I certainly know what you mean.
At least when I am done I will know that everything on this car is done the right way, because I did it the wrong way first!
Madmorrie