Carbotech brake pad overhang?
Over the winter I installed front and rear EP uprights, and in the rear I installed Lotus APR 2-pot brake calipers (same as stock Elise front calipers) and Carbotech brake pads. The rear disc rotors are AP Racing 304mm. All works well, but the rear brake pads overhang the outside of the disc by 4.3mm at the center and about 3mm near the leading and trailing edges (see photo). The Carbotech pads are part # CT109L (AX6 and XP12, both compounds fit the same).
My first thought was that the disc rotor is undersized (it's the size recommended by EP), but the minimum radial clearance between the outer edge of the disc and the caliper is only 2.4mm. There are no spacers on the caliper. I could go to a larger disc (308mm) and use spacers to fine tune the caliper position, but I can't see leaving less than 1mm of radial clearance (to accommodate thermal expansion of the disc), which would still leave about 3mm of overhang.
I have zero experience with the "standard" front brake setup (APR 2-pots with 288mm discs), so I have a couple questions. Have you seen this overhang with these same brake pads, or with other brake pads, with the "standard" front brakes? How much radial clearance is there between the disc and the caliper with the "standard" front brakes?
I'm not sure this is actually a problem. I plan to chamfer the outer edge of the pads with a file or grinder, but it clearly isn't ideal, I've never seen brake pads overhang like this before.
Thanks in advance for your thoughts, -Ed
'08 Arctic Silver Exige S240