Mark, I'll post a picture of the pads tomorrow. As you say they "but up" against the caliper shoulders, and that's where you could grind away the corners of the pad backplate to allow the pad to move closer to the hub, but the friction material is up against the raised lip of corrosion, so unless modifying with new discs it's not worth doing. Plus the fact that the exposed backplate metal will corrode. My Roadster has the previous cast iron calipers, and the same pads fit well, so clearly when the aluminium calipers were specced up, the dimensions were very slightly out.
I think on balance, doing the rear springs, although a difficult job due to access, is easier than kingpins. It's certainly quicker but just as frustrating at times. But hey, that's why I bought a trad Morgan - so I could get stuck in with the spanners.
Yes I've contemplated a manual but I'm not sure that it would be any better than what you get on here, which you can print off if you fancy doing the job. I will say this though, don't attempt kingpins on a Morgan unless you've had experience of stripping suspension on other classics, and have the right tools. It can be a challenge. The first time I did it I was finding my way, but at least now I have a tried & tested method. I very nearly bought a hydraulic press but it seemed extravagant for home use, and not many have a large enough working depth for the Morgan stub. I must ask my local village garage how much depth they have on their press. It would be more refined than 'drifting' the bushes out. Today I've cut out and hand stitched two inner leather gaiters, and later this week I'll cut out some new mohair outer gaiters. When I get chance I'll knock up a few more sets of gaiters, I've restocked with mohair for this job!!!!! I also need to get some more Velcro, probably this time without adhesive because it sticks to the sewing machine needle and I get a lot of grief for that.
No bookings John, but if I had access to a hydraulic press I could certainly do the "new bush & Reamer job".
