Custom Chinese Ti - Hydro Disc by Waltly

It might not rub now but 1mm is very close and rotors go out of true. At some point it would rub I'm sure

Yeah I have notified the manufacturer to see what they say. Definitely agree with trying it out to see though. It's just always disconcerting with tolerances that close

I can get the caliper mounted with a tiny amount of rub on the rotor (not consistent though, indicating the rotor is slightly out of true from new). There's no rub on the fork leg though yet...

Thoughts on whether a couple of the below washers placed between the hub and fork on the fork side of the disc rotor would help space the rotor away from the fork. It would allow the thru axle to tighten before it pulls the rotor close to the fork.

They would be a pain to line up each time the wheel was removed

https://www.accu.co.uk/en/shim-washers/416329-HSHN-15-21-1-A2-BL

Did you get the fork from Waltly along with the frame or did your source separately?

Fork sourced completely separately from a company called Hongfu.

Couple of ideas:

Cut a quadrant out of the spacer so you can drop it in place once the axle is in, before locking. Still going to be a fiddle though.

How is the hub itself finished? Is there an insert in the end that you could remove, and then get a machine shop/model engineer/tool maker/friend with a lathe to copy but make 1.5 or 2 mm longer?

It's a Hunt wheel with their 15mm thru axle end caps fitted.

I'll take another look at everything tonight and see.

I think your problem would be solved using centerlock rotors, mine when mounted are only 5mm from hub & spokes. Yours are way too far away from here they should be

Your rotor should be here I think

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I'm using centrelock rotors...

Could I have put them on the wrong way, is that possible? Would be slightly embarrassing if so but equally great news!

Think mine are dished one way so yeah, spin em round and see.

Checked and it is but it’s on the further out side. There’s about 3 or 4mm between rotor and fork on my Cannondale

Definitely got the rotor on the correct way... The puzzle continues

Inverse shim?

I've checked again on my bike, clearance is indeed ludicrously small.

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You'll be fine, just check your fork once in a while

Thanks for checking, good to see it can be run super close

Hopefully...

Hongfu have just replied to say they're only compatible with a 140mm rotor...

Not sure how a smaller rotor would help the very close gap between lockring and the lower edge of the brake mount on the fork

There's no real flex in the fork this close to the hub so lockring clearance won't likely be an issue.
I'm not familiar with thru axles, but I guess you should be able to fit a thin washer each side of the hub to space the fork legs a bit more apart without putting too much strain on them.

140mm rotors doesn't make sense as it's post mount, which I think is 160mm minimum.

True, my genesis is post front and rear. That runs 160 on both with no spacers or adapters. But maybe the posts would be shorter on native 140mm stuff? Frambuilding AMA>>>

Yeah that's what I thought. I queried it but according to the 'Hongfu factory' i need to use 140mm. Definitely seems like they're just fobbing me off with the wrong rotor size excuse.

Did you fit the post-mount caliber directly to the fork without an adapter for the 160mm test?

Then it is a native 160mm fork and 140mm is not an option

(maybe a sideview close up :))