Thanks for all the info guys! He has most of the parts in hand - the spacer ring, the front axle is oem "28 or 29"... The brake setup he picked up some 3 years ago. We've mounted all the parts / ran the lines / bled and went for a test ride. The front has 1 wheel locking up.

When we got back to the shop, that wheel was loose on the spindle. We had set the pre-load and pinned the nut as we all have done a hundred times. So we tore it down and I measured the wheel bearing I.D. ( inner and outer) and they have a perfect 1.5 to 2 thousandths.

We re-assembled and left the spacer ring out, and it seemed a better fit, pre-loaded the nut, pinned etc. etc.. drove it about a half mile with the same results!

Any other thoughts of things to check?