I wonder why the new rotors didnt fit over the existing huib assembly?? That seems kind of screwy to me, unless that set-up was not made for your jeep. It doesnt make sense to have to grind them down 1/8".
Well, this is an excellent, simple explanation...
The rotors/calipers/pads in question are not Jeep specific. That's why they require grinding.
...but I'm going to complicate the f*** out of it, anyway.
You can get a Centric premium rotor, a premium Bosch caliper and Black Magic pads that are all direct stock replacements. They're higher quality and they bolt right up. The rotor will be the stock 11"-and-change diameter and will fit with no issues whatsoever. When I mentioned direct-fit "pad and rotor upgrades" in previous posts I was talking about these kind of parts. Better quality, better braking, stock fitment. No modifications necessary at all.
However, the parts I installed were never
intended to fitted to the TJ's steering knuckles. The rotors are not
a direct bolt-on...nor are the calipers, the saddles, or the pads. The rotors are nearly an inch larger in diameter, have shorter hats, and have the same bolt pattern...they're actually a stock replacement for a 2005+ Explorer Sport Trac. Likewise the calipers and saddles and pads are nothing even close
to "stock replacement"...they are larger, stronger, more efficient and more powerful. The price you pay for this increased capacity is the necessity for modification.
Thus, you are quite correct to say that the components were not factory-designed to fit on a Jeep...but this does not mean that they can't be used in any given application. This is true with all parts.
for Ford 8.8 axles to fit under TJ's...but they do. Nobody intended
to be able to shoehorn Dana 60's and T-18 transmissions and portal boxes under Jeeps...but they still fit. It's just a matter of the amount of work involved to make them bolt up.
What Savvy and Vanco have done is find parts that take the least amount of modification necessary in order to be fitted on the TJ front end while still giving the massive increases in braking performance that are desired.
They do the necessary machine-work on the knuckles, provide brackets for the calipers and saddles, and package it with the best rotors, pads and calipers they can get: they form a kit that the average Jeep owner can bolt on in their garage. When you recall the fact that none
of these parts were ever designed to bolt onto a TJ, it's amazing that the unit-bearing clearance grinding is the only
thing that needs to be done.
So, long answer...but the gist of it is this: no matter that grinding was involved this kit was expressly designed to bolt onto my Jeep with a minimal amount of work.