Damn, if you were in Brizzy I know a guy with a free pair of KE70 struts with brakes etc.

damn. i found a pair for $100 locally

File them down.

Hit the brakes with the file this morning, now its got about a bee's dick of clearance, could just fit my 10 thou feeler gauge through it. how much clearance should I ideally have for expanding metals?

Dude the axle stub flexes and the wheel bearing also wears down, both add to the movement of the wheel.

Some people run a few mm but really something like 5mm at least would be reasonable. That area that is

binding is known as the X Factor and is often overlooked when considering fitment.

shit ok I'm gonna shave off a bit more then.

5mm seems a shit load to remove. That rib must of been that thick for a reason.

Alternative calipers may be the go, like ke55/70 girlocks.

yeah this is only temporary until the next pay check

The discs matched with girlock callipers are 1 or 2mm thicker than the 30/sumitomo discs so you could use your existing discs. The mount for both callipers are the same. You do need to change the rubber brake line also though as the girlock ones have an inverted flare.

As said the offset of the wheel isn't the problem, its the wheel/spoke design. I have -10 wheels on mine with plenty of clearance.

All stock brakes, 7 inch wide 14s, moulded flares unknown offset