Yeah it looks like KoKo used 5 x 1mm spacers so I'm thinking we could just mill 1mm less off the carrier.
Although I wonder if flipping the sprocket and moving the chain that little bit will cause any issues with the chain slider? I'm sure I could work that out easy enough though.
I've read on another forum that if you have a lathe big enough to accommodate chucking up the wheel, you can mill the rotor mounting point enough to use the stock caliper, so hoping to do that.
I do happen to have an 05 600rr wheel but haven't looked into using it..., might look at it this weekend.

 

Something else I noticed about the 05/06 RR wheel (I have one to, actually the whole bike) is the sprocket carrier/hub is thinner then the old F2 or 900 carrier/hub. So that might be something that helps. Also the axle/bearings are different diameter.

 

Stick with the 900rr wheel. If you need some measurments from Koko I can call him and ask if he still has them - we live in the same country and do track days on the same track

 

Yes, call him. Get him to repost those measurement in English. That will give people time to print them off for future use. Koko was on a different site after he got rid of the Evolution Bike and bought a 09 CBR1000rr but I dont see him there no more, havent for a very long time. Its been about 4 years since he posted anything, maybe he dont ride any more.

 

Maybe a newer CBR 1000 F rear wheel would be easier to rig on the F2 to get that 5.5 in. wide wheel. The newer, the wider. The older, like the 87-88, the skinnier.

 

Still trying to get some time with the fabricator / machinist.., hoping to have it done soon.
For now just bought another set of B-stone slicks...,165 rear.
I did a quick check of the 05 600rr wheel while I had the F3 on the rack, looks like the 900rr wheel will be an easier option.

 

Have been making progress..., will update with pics etc... soon.

 

Carrier was turned to the dimensions provided by Koko and I used his drawing for the carrier side captive spacer as well.
I'll be using the stock caliper / mount so I had the rotor mounting surface milled down by 6.5mm and the bearing / dust seal holder brought down as well ( having the dust seal lip milled down allows for the new spacer to fit between the caliper holder and wheel).
The right side spacer that goes between caliper mount and bearing is currently 7mm(just had the stock one milled down) however I will be going with a 22mm ID bearing on that side and having a captive spacer made once the new bearings are in.
The wheel is being sent out for truing and powder coating so I'll update after I get the new bearings and spacer made.
Thanks to all who have helped me get this far along with it!

 

Finally have it mounted up.
Runs close to the chain as expected.
Might relieve a bit from the caliper mount to gain more clearance for the rotor bolts but as it is things line up nicely with no rubbing.
Hope to go to the track in the next week or so to test.
Will follow up with more details and all the measurements etc... later.