Stuck Brake Pad Pins
I suggest pulling the axle out a bit to allow the caliper assy more freedom of movement. Then see if you can get the pins out. If not, you can put something (like a piece of wood) between the pistons and the rotor on the outside and gently pump the pedal to see if that does in fact loosen the pins.
But a more fundemental question: is the new floating rotor the EXACT diameter as the OEM (or whatever was on there) rotor? It sounds to me like the rotor is jammed against the pins. If it is the same size, are the new pads the same shape as the old ones (same profile on the metal backing)?
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