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    Re: Another brake question

    Posted by H2RICK on 5/17/2001, 10:53 pm , in reply to "Another brake question"


    I strongly recommend NOT using a drill press for this. It is NOT accurate enough.
    The disc material is a low rent grade of stainless steel. It's got just enough nickel in it to prevent rusting and cuts easily with carbide tools. It will be work hardened a little bit, depending on previous useage but not enough to wreck their tools. The last disk I had turned at the brake shop, the guy actually asked me if it was aluminum, it cut so nicely.
    The best bet is an NC (numerically controlled - actually means computerized to you and me) vertical milling machine. The trick is where to drill the holes. Here's the hard but easy way to do it. Check with someone who has a drilled disk similar in size to yours that he's happy with, if possible, and get "typical" hole diameter and pattern. Take all measurements and make a reasonably accurate sketch. Next find someone who'll do an AutoCad drawing of your disk with hole pattern on it as per your sketch. Take drawing file on diskette (or have draftsman email it to them) from draftsman to machine shop and they load it in their milling machine's controller. Throw disk onto milling machine, index disk to controller and start making chips, as they say in the machine shop business.
    Looks easy on screen but unless you are set up with guys at machine shop and have someone to do AutoCad drawing for free, get ready to shell out big bucks.
    AutoCad drawing will take about 1 hour or less for a competent draftsman or talented student. Charge should be about US$ 40 - $50 for that. Sometimes you can find guys that freelance after hours from their home. Check local Buy N Sell or Bargain Finder paper. Machine shops usually charge minimum of 1 hour including setup time so figure on about
    US$ 50 or so. The shop might also charge a "file translation" fee if their NC controller is older and cannot take AutoCad files directly, so another US$ 30 or so. When you FIRST settle on machine shop you want to use, see if they can take AutoCad files and exactly which version (release) of AutoCad...10, 11, 12,
    13, 14 or 2000 they can use. This step will probably save you some heartburn later on.
    I don't think I've forgotten anything but with something like this you'll want to think hard about it, otherwise you'll need a good supply of spare (undrilled) disks. LOLOLOLOL
    Let us know how it works out.
    PS: don't forget to countersink each side of each hole. You don't want any sharp edges chewing up your brake pucks.


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