If toyota didnt put that chassis/body mount there we wouldnt be having such a problem. If only it was half an inch further back...if only.
Spoke to Rob, before (suspension bloke), and he reckons with the lift the top of the tyre is sticking further out than it should be 6 to 7mm.
Along with that he also says based on other hilux's he's done that the castor can move the wheel forward 5 or 6 mm.
If that's the case, and hopefully I find out on Sunday, then itmight just be enough to clear that chassis mount on full lock.
Check the following pic's I took before -
You can sorta see in the first pic the trimming I did.
Coudl go that little bit more if necessary but it wont really help because the mount is the problem, as you said Formud had the same issue.
The second pick, take into account that the flares are 50mm wide whe fitted, and if the wheel alignment does in fact pull the top of the tyre inwards, then the flare would be "just" about covering the tread with the sidewall of the tyre sticking out.
Heres another pic of the tyre sticking out -
So, Ive decided to hold off on the wheel/tyre sale and will wait till I see the results from the wheel alignment.
Maate, what headaches.......:o