pics first, story later
see the inner pad sticking out past the rotor?
when I took the old parts out the old rotor was sitting like this and worn except for the outer lip which hangs over. I removed all the old top and bottom clips and replaced with the new clips supplied with my new brakes and put everything back correctly but as you can see it still hangs out.
the only thing I can think of is the lower ball joint on that side had some movement when i was really pulling on my breaker bar to break the caliper bracket bolts loose. No noticeable movement when doing the old 12 and 6 tire shake test.
I dont have a ton of money to throw at this truck to make it go away and would rather not ruin the new set of pads and rotors I just put on the truck.