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Well, it sounds like your problem is even more serious than mine - when I took the burr off the backing plate, there was still paint left on the smooth part of the edge of the backing plate, so it was still the full "nominal" length of 152mm.
Not only that, but I only deburred the backing plate on one of the four pads I installed initially, and the pads I installed on the weekend in the pad-swap had no filing done at all.
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