Originally Posted by 2005JGC
You shave off approx 1mm of material, and as mentioned alot of what is removed is just casting imperfections. For the sake of full disclosure it is NOT just a quick buzz to knock down the high spots you do level off the full face of the bracket but pretty simple and straighforward...
I did this with my last SUV (non-Jeep). I bought a set of aftermarket wheels that didn't quite fit, so I had to have the hubs bored out slightly at a machine shop. After that, I owned the wheels. When I went to mount the new wheels, they contacted the calipers.
I used an angle grinder, and ground a fair amount off the calipers. One of the guys at the machine shop suggested grinding it down, then placing a couple strips of masking tape on the caliper, mount the wheel and rotating it. If any contact is made, it will make a mark in the masking tape, and you know where you need to grind.
My calipers had ridges along the top, which is what I ground off. I probably took close to half an inch off them, so the were essentially smooth. Ran it like that for 40,000 miles or so without any problems.