After a long hot bath, here is what I come up with:
the 66 Mustang rotor/hub combination I just got, use it as the base…
1- machine the center to 81.9mm
2- machine the mounting flange to 9.2mm thickness which should make the disc 60.1mm high ( remove from wheel side)
3- machine disc to 282mm OD
4- machine bolt holes to 16.95
5- balance
6- water jet shim to offset caliper additional 1.5mm (my car had two shims on each side to bring the caliper to car center) because the disc is 1.5 mm per side further in I think we can live with that
I do not know if the flat spot on the head of the stud has something to bite on so it cannot turn. If there is nothing there could be a small recessed machined on the inside - one millimeter would do. if that’s the case… Have to go through the numbers again! Height increases to 61.1mm and caliper shim to 2.5mm
this way, we have full flange thickness, we have the proper diameter hole to center the disk on the hub, no washes needed under the studs…
If we can find a machine shop that could make the prototype and then maybe make a run of 50 .. or more??! It should become quite efficient doing same step on all and then switch for the next step on all and so on…
was my bath too hot 🥵???