Comparison photo of original disc, to the 305mm.
So probably about 4mm difference.
I cant recreate the problem with the car on stands. Even on full lock the 305 discs are nowhere near the knuckles on the LCAs, so its plainly on a problem when the suspension is under load.
Ive dressed both knuckles with the angle grinder, unfortunately theres actually less metal than I thought to (safely) play with.
I cant do anything now until the new brake pads and pins etc turn up. I know for a fact itll be friday before the pads are here, so the project is on a bit of a hiatus until then - frustrating!
Seems the solution will be a bit of trial and error and one of the following:
- The dressed knuckles have fixed it now - woo hoo!
- Dress the knuckles a little more, and that fixes it - woo hoo!
- Find some discs with a different offset and then space the callipers to match
- Space both the current discs and callipers
Spacing the callipers is no biggie it all, theres excess length available on the bolts and enough clearance to the wheels (I think!), spacing the disc in a safe manner is a different question though.
I suppose I could also revert to std. ride height, which would probably fix it too, but dont want to do that!