Thanks Mike.
The flange that part 8 sits on is 0.35mm higher than the original stock axles. This would have the effect of sitting the cup washer higher, therefore relieving the issue rather than compounding it.
Yes, you may be right and the actual head of the axle where the wheel sits may be thicker by 0.75mm - 1.0mm. This would force the rotor further inboard and may cause the contact.
Obviously last week when I fitted the first hub together, applying the 350 ft/lbs of pressure must have forced the stud heads firmly against the countersunk screws on the bearing retainer and caused the total lockup.
12.11 am in Oz so I'll get up and back to it in a few hours. It's Saturday here so I have most of the day to sort out the issue.
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