Hey guys! I just saw the thread title and thought I might poke my head in to see what it was about. I think this is probably my first post in the 1g forum.
It's cool to see people doing hard core mods on these old cars. Very rare indeed.
When I was designing the rotor-over-hub conversion for the 2g 'lude I spent quite a bit of time investigating different solutions. The two primary constraints were strength, and availability of parts. After looking at the exploded hubs (literally!), I determined that the major issue was that the cast hub/rotors were just not up to race duty. The first idea I had was to make a totally new hub that would use (probably) the stock bearings. The problem with that was that machining and material costs would be prohibitive. Changing the spindle was not really an option since finding something compatible would be exceedingly difficult at best. I looked at a lot of cars at the junkyard but nothing was even close. Reusing any part of the stock hub/rotor was out due to lack of confidence in their quality. Adding another bearing to a Civic hub is a neat idea, and would likely have worked but Dave wanted to be able to replace the hub periodically. The bearings in the newer type hubs are not replaceable so every hub would need machined for the outer bearing. Finally I discovered that a 2/3g Integra hub would fit with an adapter sleeve and was easily available. The Integra rotors are also the same size as the stock 'lude rotors so virtually no modification was needed to get the brakes to work. This was clearly the way to go so we went with it.
Something else I'll mention that I haven't really make public yet is that I've also reverse engineered the caliper mounting plate on the 2g 'lude and redesigned it to work with larger calipers and rotors. In my case I'll be using 4g Accord calipers and 10.3" Civic SI rotors. The SI rotors are the biggest you can get in 4x100 without redrilling and will be a good match for the 11" rotor setup I'll have in the front.
I still have several sets of the hub conversions left so if any of you guys are interested let me know. Or if you just need measurements of any 2g Prelude parts l can do that too.
Cheers, and happy modding!