mounting disk brake caliper problem: wheel doesn't spin freely, rubs outside pad, and caliper already as far to outside as possible Problem: 


I can't mount the caliper in such a way that the wheel spins perfectly freely (There's always a slight rub).
When the brake engages, the rotor bends slightly (because the caliper isn't centered...) 
                
            
I can't screw the caliper in far enough over to the outside so this doesn't happen... I'm guessing the bracket, where you mount the disc brake on the fork, was welded onto the fork at slightly the wrong position (i.e. a little bent, too close to the wheel)?


Question: Can I solve this myself? If I take it back to the bike shop where I bought the bike, what should I insist on?

I have a new, Bianche Volpe disc brake bike (it's steel). Hayes CX Expert mechnical disc brakes.

I know from the other disc brake bike I have that the standard way to center the caliper is to (1) squeeze the brake closed (which positions the caliper properly) and (2) screw the brake into the bracket on the fork in exactly that position!

But I can't do step 2! It's close, but it's off... Is there anything I can do? Take it back to the bike shop I bought it from? Should I insist on a new fork? Or can they work this out somehow?

It's not so bad that the bike doesn't work, but this can't be right...



Rotor and mounting bracket: (it looks like there's a slight angle and the bracket is a bit too clo
Your problem may be that you're misunderstanding mechanical disc brakes.

On most, only the outside pad moves, the disc is bent onto the inside pad. This means the loosen, clamp and tighten method doesn't work. You can do it by eye, or use a spacer between the inside pad and disk when you tighten it up.

Hayes install instructions are here.