[djpetey]

Setup
Kit: Lithium Pro Kit 700C with spokes (spokes were never used since they only fit the Alex X101)
Front Rim: Mavic CXP33
Bike: 2009 18" Norco VFR D3
Front Brakes: 160mm Avid Juicy 3 Hydraulic

issue #1: drop outs on the VFR D3 were made for the OEM shimano quick release hub axles and therefore too small for the HT axle.
solution: ground open the dropouts to accept HT hub axle.

issue #2: HT hub housing was rubbing inside of fork on non brake rotor side.
solution: HT hub housing had to be ground at an angle to clear fork

issue #3: 160mm caliper setup did not clear HT hub.
solution: 203mm rotor and caliper adapter required to clear HT hub.

issue #4 (current issue) : insufficient rotor to spoke clearance for avid juicy 3 caliper at 203mm. 18mm clearance required but only 16mm clearance available.
solution option #1: upgrade caliper to <16mm housing. ie shimano XT/XTR, avid elixer, magura louise. (cost prohibitive)
solution option #2: re build wheel with half radial spoking (head out, radial lacing pattern) on rotor side only to create more clearance. [note: full radial spoking should NOT be used due to torque stress of being a drive and brake wheel. full radial lacing is only recommended for front free wheels only]

I will update this post as soon as i attempt the half radial spoking build. if i still don't have enough clearance i may need to grind down my brake caliper. if that doesn't work i will have to upgrade to one of the thinner above mentioned hydraulic calipers, or downgrade to a Hayes MX4 mechanical setup which i already successfully test fitted.

[djpetey]

update:
half radial pattern not recommended by most wheel builders due to both drive and braking torque stresses. hub integrity in question for radial pattern since stress patterns are not the same with cross lacing patterns. 2-cross or crows foot lacing patterns being considered. stay tuned for more updates.

[totcycle]

what's the word? we're trying to figure this out over here:
will-disc-brake-motor-fit-my-disc-brakes-yes-t146.html

[Jacob]

To update yall, the only adjustment I had to make on my 2005 Giant Yukon with disc brakes was to file the drop outs to accomodate the thickness of the hilltopper axle and the included washers that stops the axle from spinning. I put both of the "inner" washers that came with the hilltopper on the disc brake side, that gave me enough clearance for the spokes not to hit the caliper and found another thinner washer that I substituted on the right side. Then to make the disc rotor fit perfectly between the caliper pads I took away the rubber gasket that came with the hub and added 2 small washers on the inside of every bolt that held the disc rotor to the hub. It runs perfectly!