I have an old Gitane track bike and the front fork is spaced 94mm. I have the original wheels but they are attached to old tubular rims which I find inconvenient for city riding.
I would like to either re-build the wheels with new clincher rims around the original hubs (Normandy with single sided fixed rear - high flange) OR just buy new wheels and leave the originals intact for a future owner to enjoy. Anybody know who makes a modern front hub that can have the spacers adjusted down to 94mm?
I tried spreading the fork blades a little, but 6mm is a lot and those round track fork blades are STIFF.
Sneldon answers your second question with sandpaper. http://sheldonbrown.com/velos.html
0.2 mm is not a lot of material to remove.
As to the first. Could you loose 1mm from the outside face of the cone and 1 mm from the thickness of the locknut with a grinder? This would loose you 4 mm overall.