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cookflys

Joined: 13 Jan 2009
Posts: 17
Location: atlanta

Posted: Thu Feb 12, 2009 9:10 pm Post subject: Brake rotors

I noticed that my model II Matco brakes has a rotor that has lighting holes drilled all over. The newer brake assembly that came off a model IV  that I am installing does not. Has anybody heard if there has been a problem with the older rotors?



Charles Cook 

N363KF  582 

ATL

         [quote][b]

_________________
Charles Cook
Model II 582
#363

akflyer

Joined: 07 May 2007
Posts: 574
Location: Soldotna AK

Posted: Thu Feb 12, 2009 9:40 pm Post subject: Re: Brake rotors

no problem.  They came solid and people drilled them out to save weight.  I have a set of each also.  I used the drilled ones as they were noticeably lighter.

_________________
DO NOT ARCHIVE
Leonard Perry aka SNAKE
Soldotna AK
Avid "C" / Mk IV
582 (147 hrs and counting on the rebuild)
IVO IFA
Full Lotus 1450
#1 snake oil salesman since 1-22-2009

I would rather die trying to live, than to live trying not to die....

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Fri Feb 13, 2009 6:04 am Post subject: Brake rotors

My Model IV manual shows the lightening holes in the brake rotors to  

be an owner-modified option. I did the drilling and cutting on mine,  

and have had no problems whatsoever in over 600 hours.



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062, 605 hrs

Sensenich 62x46

Electroair direct-fire ignition system

New skis done and flying





On Feb 13, 2009, at 12:09 AM, charles cook wrote:



 	  Quote: 	
		   I noticed that my model II Matco brakes has a rotor that has  

 lighting holes drilled all over. The newer brake assembly that came  

 off a model IV  that I am installing does not. Has anybody heard if  

 there has been a problem with the older rotors?



 Charles Cook

 N363KF  582

 ATL

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

Roger Lee

Joined: 10 Jan 2006
Posts: 1464
Location: Tucson, Az.

Posted: Fri Feb 13, 2009 7:09 am Post subject: Re: Brake rotors

Matco as of recent has started to lighten up their brake systems. I believe this was due to several factors. One being the LSA Mfg's wanted lighter brakes for aircraft sold overseas. Their weight limit for the plane is 450Kgs instead of our 600kgs. This was an issue for Flight Design planes where these Mfg's count ounces and not lbs.. I am an OEM for Matco brakes. Also it would stand to make since that less material used in the entire Matco brake line products would add up to lowering cost. The older rotors were quite thick and heavy. Now many newer rotors are thinner and have debris/water removing groves cut in. In the last year they have done some redesigning. They have made a flange mount brake for the Flight Design round axle socket so it can be adjusted for toe-in and out plus camber. They have been great to work with.

_________________
Roger Lee
Tucson, Az.
Rotax Instructor & Rotax IRC
Light Sport Repairman
Home 520-574-1080 TRY HOME FIRST
Cell 520-349-7056

clint_bazzill(at)hotmail.
Guest

Posted: Fri Feb 13, 2009 9:08 am Post subject: Brake rotors

I also drilled and cut to save weight.  With a 912UL had a hard time holding the airplane on runup.  Did fast runups C bought new rotors C cut extra material on outside but drilled no holes.  That worked with the 912UL and can hold my 912ULS now.  With a 72 inch 3 blade prop and 912ULS a lot of thrust.  Should be no problem with a Jabiru.

 Clint

 	  Quote: 	
		   From: lynnmatt(at)jps.net

 Subject: Re: Kitfox-List: Brake rotors

 Date: Fri C 13 Feb 2009 09:03:46 -0500

 To: kitfox-list(at)matronics.com

 --> Kitfox-List message posted by: Lynn Matteson <lynnmatt(at)jps.net>

 My Model IV manual shows the lightening holes in the brake rotors to 

 be an owner-modified option. I did the drilling and cutting on mine C 

 and have had no problems whatsoever in over 600 hours.

 Lynn Matteson

 Kitfox IV Speedster C taildragger

 Jabiru 2200 C #2062 C 605 hrs

 Sensenich 62x46

 Electroair direct-fire ignition system

 New skis done and flying

 On Feb 13 C 2009 C at 12:09 AM C charles cook wrote:

 > I noticed that my model II Matco brakes has a rotor that has 

 > lighting holes drilled all over. The newer brake assembly that came 

 > off a model IV that I am installing does not. Has anybody heard if 

 > there has been a problem with the older rotors?

 >

 > Charles Cook

 > N363KF 582

&gt=====================

 	  Quote: 	
		   _=====

  [quote][b]

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Fri Feb 13, 2009 10:16 am Post subject: Brake rotors

I don't know about that last statement, Clint....I was flying the  

other day and I held the brakes as hard as I could and I couldn't  

hold the Jabiru back. : )



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062, 605 hrs

Sensenich 62x46

Electroair direct-fire ignition system

New skis done and flying

do not archive



On Feb 13, 2009, at 12:07 PM, Clint Bazzill wrote:



 	  Quote: 	
		   I also drilled and cut to save weight.  With a 912UL had a hard  

 time holding the airplane on runup.  Did fast runups, bought new  

 rotors, cut extra material on outside but drilled no holes.  That  

 worked with the 912UL and can hold my 912ULS now.  With a 72 inch 3  

 blade prop and 912ULS a lot of thrust.  Should be no problem with a  

 Jabiru.

 Clint

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

clint_bazzill(at)hotmail.
Guest

Posted: Fri Feb 13, 2009 11:37 am Post subject: Brake rotors

I have flown in Jabiru 2200 and 3300 powered airplanes.  The thrust at take off with a 62 inch wooden prop is nothing like a 912ULS with 3 blades 72 inch.  Believe me.

  

 Clint



 	  Quote: 	
		   From: lynnmatt(at)jps.net

 Subject: Re: Kitfox-List: Brake rotors

 Date: Fri C 13 Feb 2009 13:15:12 -0500

 To: kitfox-list(at)matronics.com

 

 --> Kitfox-List message posted by: Lynn Matteson <lynnmatt(at)jps.net>

 

 I don't know about that last statement C Clint....I was flying the 

 other day and I held the brakes as hard as I could and I couldn't 

 hold the Jabiru back. : )

 

 Lynn Matteson

 Kitfox IV Speedster C taildragger

 Jabiru 2200 C #2062 C 605 hrs

 Sensenich 62x46

 Electroair direct-fire ignition system

 New skis done and flying

 do not archive

 

 

 

 On Feb 13 C 2009 C at 12:07 PM C Clint Bazzill wrote:

 

 > I also drilled and cut to save weight. With a 912UL had a hard 

 > time holding the airplane on runup. Did fast runups C bought new 

 > rotors C cut extra material on outside but drilled no holes. That 

 > worked with the 912UL and can hold my 912ULS now. With a 72 inch 3 

 > blade prop and 912ULS a lot of thrust. Should be no problem with a 

 > Jabiru.

 >

 >

=======================

 

 

 


	


  [quote][b]

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Fri Feb 13, 2009 12:03 pm Post subject: Brake rotors

I understand, Clint, and I believe you. But re-read my post....pay  

particular attention to the words "was flying"....that's the key here  

to my little joke. : )



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062, 605 hrs

Sensenich 62x46

Electroair direct-fire ignition system

New skis done and flying

do not archive



On Feb 13, 2009, at 2:36 PM, Clint Bazzill wrote:



 	  Quote: 	
		   I have flown in Jabiru 2200 and 3300 powered airplanes.  The thrust  

 at take off with a 62 inch wooden prop is nothing like a 912ULS  

 with 3 blades 72 inch.  Believe me.



 Clint



 > From: lynnmatt(at)jps.net

 > Subject: Re: Brake rotors

 > Date: Fri, 13 Feb 2009 13:15:12 -0500

 > To: kitfox-list(at)matronics.com

 >

 > 

 >

 > I don't know about that last statement, Clint....I was flying the

 > other day and I held the brakes as hard as I could and I couldn't

 > hold the Jabiru back. : )

 >

 > Lynn Matteson

 > Kitfox IV Speedster, taildragger

 > Jabiru 2200, #2062, 605 hrs

 > Sensenich 62x46

 > Electroair direct-fire ignition system

 > New skis done and flying

 > do not archive

 >

 >

 >

 > On Feb 13, 2009, at 12:07 PM, Clint Bazzill wrote:

 >

 > > I also drilled and cut to save weight. With a 912UL had a hard

 > > time holding the airplane on runup. Did fast runups, bought new

 > > rotors, cut extra material on outside but drilled no holes. That

 > > worked with the 912UL and can hold my 912ULS now. With a 72 inch 3

 > > blade prop and 912ULS a lot of thrust. Should be no problem with a

 > > Jabiru.

 > >

 > >

 >=======================

 >

 >

 >



 ============================================================ _- 

 ============================================================ _- 

 contribution_- 

 ============================================================

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

clint_bazzill(at)hotmail.
Guest

Posted: Fri Feb 13, 2009 12:17 pm Post subject: Brake rotors

I guess that is what it is.

  

 Clint



 	  Quote: 	
		   From: lynnmatt(at)jps.net

 Subject: Re: Kitfox-List: Brake rotors

 Date: Fri C 13 Feb 2009 15:02:23 -0500

 To: kitfox-list(at)matronics.com

 

 --> Kitfox-List message posted by: Lynn Matteson <lynnmatt(at)jps.net>

 

 I understand C Clint C and I believe you. But re-read my post....pay 

 particular attention to the words "was flying"....that's the key here 

 to my little joke. : )

 

 Lynn Matteson

 Kitfox IV Speedster C taildragger

 Jabiru 2200 C #2062 C 605 hrs

 Sensenich 62x46

 Electroair direct-fire ignition system

 New skis done and flying

 do not archive

 

 

 

 On Feb 13 C 2009 C at 2:36 PM C Clint Bazzill wrote:

 

 > I have flown in Jabiru 2200 and 3300 powered airplanes. The thrust 

 > at take off with a 62 inch wooden prop is nothing like a 912ULS 

 > with 3 blades 72 inch. Believe me.

 >

 > Clint

 >

 > > From: lynnmatt(at)jps.net

 > > Subject: Re: Brake rotors

 > > Date: Fri C 13 Feb 2009 13:15:12 -0500

 > > To: kitfox-list(at)matronics.com

 > >

 > > --> Kitfox-List message posted by: Lynn Matteson <lynnmatt(at)jps.net>

 > >

 > > I don't know about that last statement C Clint....I was flying the

 > > other day and I held the brakes as hard as I could and I couldn't

 > > hold the Jabiru back. : )

 > >

 > > Lynn Matteson

 > > Kitfox IV Speedster C taildragger

 > > Jabiru 2200 C #2062 C 605 hrs

 > > Sensenich 62x46

 > > Electroair direct-fire ignition system

 > > New skis done and flying

 > > do not archive

 > >

 > >

 > >

 > > On Feb 13 C 2009 C at 12:07 PM C Clint Bazzill wrote:

 > >

 > > > I also drilled and cut to save weight. With a 912UL had a hard

 > > > time holding the airplane on runup. Did fast runups C bought new

 > > > rotors C cut extra material on outside but drilled no holes. That

 > > > worked with the 912UL and can hold my 912ULS now. With a 72 inch 3

 > > > blade prop and 912ULS a lot of thrust. Should be no problem with a

 > > > Jabiru.

 > > >

 > > >

 > >=======================

 > >

 > >

 > >

 >

 > =================================== _- 

 > ========== _- 

 > contribution_- 

 > ============================================

&gt======
	


 	  Quote: 	
		   

 

 


	


  [quote][b]

jcrowder(at)lpbroadband.n
Guest

Posted: Fri Feb 13, 2009 3:24 pm Post subject: Brake rotors

Hey Lynn,

Were you on your skis? ;>)

Jim Crowder

Do not archive



[quote] --

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Fri Feb 13, 2009 6:28 pm Post subject: Brake rotors

Yes, I was....hey!  maybe that's the reason I couldn't stop in mid- 

air....my skis were skidding over the clouds!  Well, no freakin'  

wonder.....



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062, 605 hrs

Sensenich 62x46

Electroair direct-fire ignition system

New skis done and flying

do not archive



On Feb 13, 2009, at 6:21 PM, Jim Crowder wrote:



[quote] 

 <jcrowder(at)lpbroadband.net>



 Hey Lynn,

 Were you on your skis? ;>)

 Jim Crowder

 Do not archive



> --

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Fri Feb 13, 2009 8:04 pm Post subject: Brake rotors

Ooops......hey, Snakeman, better dust off one of those "humorless  

darwin awards"...I think we have a candidate. 



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062, 605 hrs

Sensenich 62x46

Electroair direct-fire ignition system

New skis done and flying

do not archive



On Feb 13, 2009, at 3:16 PM, Clint Bazzill wrote:



 	  Quote: 	
		   I guess that is what it is.



 Clint



 > From: lynnmatt(at)jps.net

 > Subject: Re: Brake rotors

 > Date: Fri, 13 Feb 2009 15:02:23 -0500

 > To: kitfox-list(at)matronics.com

 >

 > 

 >

 > I understand, Clint, and I believe you. But re-read my post....pay

 > particular attention to the words "was flying"....that's the key  

 here

 > to my little joke. : )

 >

 > Lynn Matteson

 > Kitfox IV Speedster, taildragger

 > Jabiru 2200, #2062, 605 hrs

 > Sensenich 62x46

 > Electroair direct-fire ignition system

 > New skis done and flying

 > do not archive

 >

 >

 >

 > On Feb 13, 2009, at 2:36 PM, Clint Bazzill wrote:

 >

 > > I have flown in Jabiru 2200 and 3300 powered airplanes. The thrust

 > > at take off with a 62 inch wooden prop is nothing like a 912ULS

 > > with 3 blades 72 inch. Believe me.

 > >

 > > Clint

 > >

 > > > From: lynnmatt(at)jps.net

 > > > Subject: Re: Brake rotors

 > > > Date: Fri, 13 Feb 2009 13:15:12 -0500

 > > > To: kitfox-list(at)matronics.com

 > > >

 > > > 

 <lynnmatt(at)jps.net>

 > > >

 > > > I don't know about that last statement, Clint....I was flying  

 the

 > > > other day and I held the brakes as hard as I could and I  

 couldn't

 > > > hold the Jabiru back. : )

 > > >

 > > > Lynn Matteson

 > > > Kitfox IV Speedster, taildragger

 > > > Jabiru 2200, #2062, 605 hrs

 > > > Sensenich 62x46

 > > > Electroair direct-fire ignition system

 > > > New skis done and flying

 > > > do not archive

 > > >

 > > >

 > > >

 > > > On Feb 13, 2009, at 12:07 PM, Clint Bazzill wrote:

 > > >

 > > > > I also drilled and cut to save weight. With a 912UL had a hard

 > > > > time holding the airplane on runup. Did fast runups, bought  

 new

 > > > > rotors, cut extra material on outside but drilled no holes.  

 That

 > > > > worked with the 912UL and can hold my 912ULS now. With a 72  

 inch 3

 > > > > blade prop and 912ULS a lot of thrust. Should be no problem  

 with a

 > > > > Jabiru.

 > > > >

 > > > >

 > > >=======================

 > > >

 > > >

 > > >

 > >

 > > =================================== _-

 > > ========== _-

 > > contribution_-

 > > ============================================

 >======

 >

 >

 >



 ============================================================ _- 

 ============================================================ _- 

 contribution_- 

 ============================================================

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

akflyer

Joined: 07 May 2007
Posts: 574
Location: Soldotna AK

Posted: Fri Feb 13, 2009 9:39 pm Post subject: Re: Brake rotors

 	  Lynn Matteson wrote: 	
		  Ooops......hey, Snakeman, better dust off one of those "humorless  

darwin awards"...I think we have a candidate. 



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062, 605 hrs

Sensenich 62x46

Electroair direct-fire ignition system

New skis done and flying

do not archive

	




Me thinks some one is trying to get me black listed again.... I nibbled, but ya didnt get me to swallow the hook.





Who am I kidding.....



You sir, have just been nominated, seconded and now handed out..







wait for it





A humorless Darin award.



as you are still breathing, this one is just for killing humor, in a unique way.



who wants one in 2010

Snake

patreilly43(at)hotmail.co
Guest

Posted: Sat Feb 14, 2009 12:48 am Post subject: Brake rotors

Chuck C The lightening holes in the rotors is an owner install option. It is described in my model 3 assembly book. The original owner / builder did not drill the rotors. I drilled them in my rebuild. Could be wrong but C I don't believe you will find any of the OEM rotors already drilled. Automotive race applications all use cross drilled rotors with much greater forces applied to the rotors. Should be fine on a KF. 

Pat Reilly

Mod 3 582 Rebuild

Rockford C IL

 	  Quote: 	
		   From: lynnmatt(at)jps.net

 Subject: Re: Kitfox-List: Brake rotors

 Date: Fri C 13 Feb 2009 09:03:46 -0500

 To: kitfox-list(at)matronics.com

 --> Kitfox-List message posted by: Lynn Matteson <lynnmatt(at)jps.net>

 My Model IV manual shows the lightening holes in the brake rotors to 

 be an owner-modified option. I did the drilling and cutting on mine C 

 and have had no problems whatsoever in over 600 hours.

 Lynn Matteson

 Kitfox IV Speedster C taildragger

 Jabiru 2200 C #2062 C 605 hrs

 Sensenich 62x46

 Electroair direct-fire ignition system

 New skis done and flying

 On Feb 13 C 2009 C at 12:09 AM C charles cook wrote:

 > I noticed that my model II Matco brakes has a rotor that has 

 > lighting holes drilled all over. The newer brake assembly that came 

 > off a model IV that I am installing does not. Has anybody heard if 

 > there has been a problem with the older rotors?

 >

 > Charles Cook

 > N363KF 582

 > ATL

 >

 >

 _-===============================================

&g=======

[quote] 

   	  Quote: 	
		  [b]

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Sat Feb 14, 2009 3:48 am Post subject: Brake rotors

I offer the following as a substitute for a NASA Form 277 (get out of  

jail free)...Snake will know what I mean....and maybe Guy will too. : )



Charles-

Here is what the lightened rotors look like....as you can see, just  

cutting off the material that just goes along for the ride quite a  

bit of relative weight is saved. I weighed mine at the time of the  

operation, and the original disc weighed 1#, 10 oz. and after  

drilling and cutting weighed 13 oz., so the weight is cut in half.

For further lightening, you can drill the axles, also shown on the  

original drawing in the builder's manual. I did this as well, and  

saved a further 6 oz., but I didn't record at the time if this was  

one axle or both...either way is wasn't much.



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062, 605 hrs

Sensenich 62x46

Electroair direct-fire ignition system

New skis done and flying

 	  Quote: 	
		  

 >

 > On Feb 13, 2009, at 12:09 AM, charles cook wrote:

 >

 > > I noticed that my model II Matco brakes has a rotor that has

 > > lighting holes drilled all over. The newer brake assembly that  

 came

 > > off a model IV that I am installing does not. Has anybody heard if

 > > there has been a problem with the older rotors?

 > >

 > > Charles Cook

 > > N363KF 582

 > > ATL

 > >

 > >

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_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

patreilly43(at)hotmail.co
Guest

Posted: Sat Feb 14, 2009 11:18 am Post subject: Brake rotors

Lynn C I drilled mine. But C was wondering how you cut off the outside edge between the mounting tabs. Can't use a lathe C which I don't have anyway C because you'd cut off the tab also. I imagine I removed a little less than 1/2 the weight you did by removing the outside edge.



Pat Reilly

Mod 3 582 Rebuild

Rockford C IL





[quote] From: lynnmatt(at)jps.net

 Subject: Re: Brake rotors

 Date: Sat C 14 Feb 2009 06:43:58 -0500

 To: kitfox-list(at)matronics.com

 

 I offer the following as a substitute for a NASA Form 277 (get out of 

 jail free)...Snake will know what I mean....and maybe Guy will too. : )

 

 Charles-

 Here is what the lightened rotors look like....as you can see C just 

 cutting off the material that just goes along for the ride quite a 

 bit of relative weight is saved. I weighed mine at the time of the 

 operation C and the original disc weighed 1# C 10 oz. and after 

 drilling and cutting weighed 13 oz. C so the weight is cut in half.

 For further lightening C you can drill the axles C also shown on the 

 original drawing in the builder's manual. I did this as well C and 

 saved a further 6 oz. C but I didn't record at the time if this was 

 one axle or both...either way is wasn't much.

 

 

 

   	  Quote: 	
		  [b]

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Sat Feb 14, 2009 1:20 pm Post subject: Brake rotors

As you can see by the picture, I drilled a large...can't recall the  

size, maybe 7/16"... hole so that the edge was tangent to what would  

become the new outer diameter of the rotor proper, then bandsawed the  

rest of the material away. Previously, I had "painted" the whole  

rotor with Dykem blue layout dye, and marked out each hole and cut- 

line with a scribe. Then it was just a simple matter of doing the  

drilling and the sawing....pretty standard metal-removing tactics for  

a home shop...with a bandsaw, of course. Any local machine shop could  

do it if you don't have the saw.



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062, 605 hrs

Sensenich 62x46

Electroair direct-fire ignition system

New skis done and flying





On Feb 14, 2009, at 2:17 PM, patrick reilly wrote:



 	  Quote: 	
		   Lynn, I drilled mine. But, was wondering how you cut off the  

 outside edge between the mounting tabs. Can't use a lathe, which I  

 don't have anyway, because you'd cut off the tab also. I imagine I  

 removed a little less than 1/2 the weight you did by removing the  

 outside edge.



 Pat Reilly

 Mod 3 582 Rebuild

 Rockford, IL

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

patreilly43(at)hotmail.co
Guest

Posted: Sat Feb 14, 2009 2:25 pm Post subject: Brake rotors

Lynn C OK C thanks for the info. I have a craftsman 12" bandsaw I use on wood and occasionally aluminum. I don't think it is powerful enough to cut steel 1/4" thick. What bandsaw and blade did you use? I drilled mine after laying out per builders manual similar to you. If I take my wheels off and have the time I will either buy a bigger bandsaw or lay it out C drill the holes and have a machine shop saw off the outer rim. 

Pat Reilly

Mod 3 582 Rebuild

Rockford C IL

[quote] From: lynnmatt(at)jps.net

 Subject: Re: Brake rotors

 Date: Sat C 14 Feb 2009 16:19:45 -0500

 To: kitfox-list(at)matronics.com

 --> Kitfox-List message posted by: Lynn Matteson <lynnmatt(at)jps.net>

 As you can see by the picture C I drilled a large...can't recall the 

 size C maybe 7/16"... hole so that the edge was tangent to what would 

 become the new outer diameter of the rotor proper C then bandsawed the 

 rest of the material away. Previously C I had "painted" the whole 

 rotor with Dykem blue layout dye C and marked out each hole and cut- 

 line with a scribe. Then it was just a simple matter of doing the 

 drilling and the sawing....pretty standard metal-removing tactics for 

 a home shop...with a bandsaw C of course. Any local machine shop could 

 do it if you don't have the saw.

 Lynn Matteson

 Kitfox IV Speedster C taildragger

 Jabiru 2200 C #2062 C 605 hrs

 Sensenich 62x46

 Electroair direct-fire ignition system

 New skis done and flying

 On Feb 14 C 2009 C at 2:17 PM C patrick reilly wrote:

 > Lynn C I drilled mine. But C was wondering how you cut off the 

 > outside edge between the mounting tabs. Can't use a lathe C which I 

 > don't have anyway C because you'd cut off the tab also. I imagine I 

 > removed a little less than 1/2 the weight you did by removing the 

 > outside edge.

 >

 > Pat Reilly

 > Mod 3 582 Rebuild

 > =====================

 _=====

   	  Quote: 	
		  [b]

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Sat Feb 14, 2009 3:54 pm Post subject: Brake rotors

Pat-

Don't even try to use a wood bandsaw for steel unless you can reduce  

the speed from the wood speed of approximately 2500 blade-feet-per- 

minute, to about 675 bfpm for the steel. Then you need to use at  

least a "general use" saw blade with (at the least) about 18 teeth- 

per-inch (TPI). I have an old Delta bandsaw that has a speed reducing  

gearbox, and that's about the only good way to get the blade speed  

reduced. You can try to make a jackshaft for your machine, but it  

takes some pretty big...and small...pulleys to get the speed down to  

where it is safe to cut steel. And the blade needs to say on the  

package that it's for steel...it will have the aforementioned fine  

teeth, and a blue color. There should always be at least two teeth in  

contact with the metal at any time during the cutting.



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062, 605 hrs

Sensenich 62x46

Electroair direct-fire ignition system

New skis done and flying

On Feb 14, 2009, at 5:24 PM, patrick reilly wrote:



 	  Quote: 	
		   Lynn, OK, thanks for the info. I have a craftsman 12" bandsaw I use  

 on wood and occasionally aluminum. I don't think it is powerful  

 enough to cut steel 1/4" thick. What bandsaw and blade did you use?  

 I drilled mine after laying out per builders manual similar to you.  

 If I take my wheels off and have the time I will either buy a  

 bigger bandsaw or lay it out, drill the holes and have a machine  

 shop saw off the outer rim.



 Pat Reilly

 Mod 3 582 Rebuild

 Rockford, IL



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Lynn
Kitfox IV-Jabiru 2200
N369LM

edgraydallas

Joined: 13 Jun 2008
Posts: 74
Location: Dallas, Tx

Posted: Sun Feb 15, 2009 9:17 am Post subject: Brake rotors

Lynn and Patrick,  I would remove the outer rim of the rotors by making 4 or 5 radial cuts with an angle grinder and cutoff wheel, up to the outer radius desired for each segment to be removed (like slicing a pie).  Then lop of the segments with the cutoff wheel and round off the circumference with a grinder wheel on the same machine and dress with a file.  No need for a band saw here.  I didn’t bother because the weight savings seemed small, but next time the rotors are off I will.  I also drilled my axles one inch and tapped them for a 5/16 bolt for future wheel pants.  Then I made a  C shaped clip out of thick steel wire to pin the axle bolt and eliminate the cotter.  Now I can drill the axle dust caps, and install a stud to stabilize the pants.  I want to fly it a bit before adding the wheel pants.  Got the engine and radiator in this weekend.  I vented the cylinder head into the water line exiting the head above the oil pump since my water fill tank has no nipple.  Any 582 guys see any problem with this?  I also didn’t like the use of only three bolts for the exhaust manifold, so I put  short studs in the upper inside holes and can put  nuts on it by tightening the two nuts gradually as the manifold goes on.  I had to grind a little weld material from the flange so the nuts are seated flush.  Worked great.   

   

I am now debating whether to add a Hacman control before completion.  Any comments about this decision are welcome.   

   

Ed Gray, KII, 582 building, Dallas , do not archive  

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