I've never seen a failure like you describe, glad you caught it

I've rebuilt my calipers a few times, so I sort of grok how the system operates... there's
not much to the calipers...
I can't relate to how one caliper could be affected in any way by the thickness of
the other caliper's rotor.
Once a rotor gets too thin, there will be too much piston sticking out based on
some informed calculation by some engineer. Or the rotor will be to thin to
stand up to the forces acting upon it, based on some similar informed calculation.
But if both your rotors are "good", I wouldn't think it would matter if they
were exactly the same thickness...
-Mike "mildly informed in a hands-on non-calculus based way

"