Dear alltrac.net I've found a solution, it's taken three years, 30+ rotors and lots off my time. I felt like the great mouse detective, but tonight I ended my search.
The front rotors require zero machine work, zero shiming, zero drilling(you could make them 5x100 very easily,I would've I'd the scion tc wheels fit!) The clearance ball joint to rotor is approx 5mm at full lock. The caliper/spindle need 2mm to be shaved.
The rears are exact bolt on, no bs, nothing.
When I got my front calipers I didn't get 205 rotors which made it ALLOT harder cause I was using other people's measurements from all over the inform nets.
My biggest problem is wheels, I've found a buddys alltrac that they fit.
It all started when I was writing my second job, guy brings new a rotor to turn...bam, it looked right, I've handled so many rotors by then I could eye ball size. It was spot on for the rears, then the fronts were the trick, over 100 hours off running numbers, making exceptions, and then in the middle of work, bam.
I'm not disclosing what I did, or am using for this obvious reason...I've spent so much money and time, it wasn't free to me or my wife. You COULD find out the way I did. But I'm unfairly nut going to post what it is. Several users have bugged for months, so here's proof.
The biggy is hub centering rings! The only down side to this, and longer studs.
For around $175 you can get all the rotors I used, I just bought another hub set fir $150 then calipers are around 5-600 if you aren't as lucky as I've been.