Just as an update I ended up with the following parts list:
- TJ hubs
- Explorer rotors
- JKS spacers
The modifications I needed to make are:
- I had a friend take .020" off the outside of the hub flanges on his lathe. I wanted it to be a clean job so I went this route. Bottom line is that the hubs are a hair too big for the rotors to fit over the outer edge. Machining the hubs means that any future rotor purchases will be a drop-in (some people grind the inside of the rotors instead).
- I will need to space the rotor off the hub by ~2MM. 2.63MM is a hair too much which is how I honed in on 2MM (I had some washers that measured out to that) but I am still working it out. The difference between the height of the WJ rotor and the Explorer rotor is .1" which is 2.54MM so logic would say that 1.25MM would be the ticket BUT in reality it seems to need to be a little more than that. Once I work it out I will post up my findings.
That should be it. The 2MM spacing of the rotor is NOT enough to pull the rotor off the locating ridge on the hub.
As for HOW I am going to space it I haven't decided on that yet either. I ordered a pile of 2MM round shims (Washers but much tighter tolerances) from McMaster but I'd prefer a 1-piece spacer. I have a 3MM wheel spacer that fits inside the rotor. I may have that milled down to 2MM.
Why am I spacing the rotor? As stated earlier the Explorer rotor is .1" taller which moves the face of the rotor closer to the caliper bracket. With no spacer the clearance between the rotor and the bracket is less than 1MM.
TJ hubs machined down:
Explorer rotor on TJ hub:
Clearance with 2.63MM spacers:
TJ hub, spacer and knuckle (spacers still need to be welded on):