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PhilDAS-
I don't think the rotor size will make a difference as it is also really tight at the bottom of the fork (where a reduced 140mm disc would still rotate in). I'd also really not have to replace the hubs.
I've contacted the fork manufacturer regarding the issue to see what they say!
If I could put a spacer between the inside of the dropout and the wheel axle that would push the rotor away from the fork leg a bit. I don't know if such spacers exist though
Saffronspokes
That is the fear - not sure what the fix is or why it is so close though?