Post by Just Plain Bill on Nov 3, 2008 16:08:23 GMT -5
I was considering using a FZR600 rotor and 4 piston caliper but the caliper wouldn't clear the wire spokes no matter how much the rotor was offset from the wheel hub. I had a set of worn out FZR rotors which have the same mounting bolt pattern as the SR rotors and it occurred to me that I could simply bolt the FZR and SR rotors together and use the holes in the FZR rotors as a guide to drill my SR parts. I also thought that others wanting drilled rotors might benefit by seeing photos of the process, which accounts for the following:
The photo below shows just three 8mm bolts holding the rotors together, I actually used all six bolts when I drilled the rotors. Incidentally, this is a job you only want to do on a drill press, with the speed set at the slowest level possible (300 rpm is ideal). Because the SR rotor is stainless steel, you should use a cobalt drill bit (19/64ths or 5/16ths inch) for ease of drilling and it's ability to stay sharp and make accurate holes under high heat operation.
Because the SR rotor has a wider area swept by the brake pad than the FZR, I needed one more row of holes to cover the inner diameter of the SR braking surface. As you can see in the photo below, I followed the pattern of three holes angling forward and back with a fourth hole to produce a "V" effect. If you look closely, you will see that I just estimated the placement of those fourth holes instead of laying them out like a more particular craftsman might.
When the drilling operation was finished, I followed up by counter sinking (chamfering) the new holes in the SR rotor. This is to remove burrs and produce a smooth surface. I used a chamfering tool but you can achieve the same thing using a large (half inch or so) drill bit and lightly touching the hole to remove just enough material to leave a slightly beveled edge.
Now that I've completed drilling my rotors, I have some worn out FZR rotors I will send to forum members who need a pattern to drill their SR rotors, for the cost of postage. The only condition is that they pass them on in the same way when finished if asked by another forum member. We can use this thread to track the rotors; just post when you receive and when you are ready to send a rotor. If no one needs them in before year's end (2008), I'll just toss them on my metal recycling pile and they'll turn up in your next "made in China" tool or motorcycle.
Bill
The photo below shows just three 8mm bolts holding the rotors together, I actually used all six bolts when I drilled the rotors. Incidentally, this is a job you only want to do on a drill press, with the speed set at the slowest level possible (300 rpm is ideal). Because the SR rotor is stainless steel, you should use a cobalt drill bit (19/64ths or 5/16ths inch) for ease of drilling and it's ability to stay sharp and make accurate holes under high heat operation.
Because the SR rotor has a wider area swept by the brake pad than the FZR, I needed one more row of holes to cover the inner diameter of the SR braking surface. As you can see in the photo below, I followed the pattern of three holes angling forward and back with a fourth hole to produce a "V" effect. If you look closely, you will see that I just estimated the placement of those fourth holes instead of laying them out like a more particular craftsman might.
When the drilling operation was finished, I followed up by counter sinking (chamfering) the new holes in the SR rotor. This is to remove burrs and produce a smooth surface. I used a chamfering tool but you can achieve the same thing using a large (half inch or so) drill bit and lightly touching the hole to remove just enough material to leave a slightly beveled edge.
Now that I've completed drilling my rotors, I have some worn out FZR rotors I will send to forum members who need a pattern to drill their SR rotors, for the cost of postage. The only condition is that they pass them on in the same way when finished if asked by another forum member. We can use this thread to track the rotors; just post when you receive and when you are ready to send a rotor. If no one needs them in before year's end (2008), I'll just toss them on my metal recycling pile and they'll turn up in your next "made in China" tool or motorcycle.
Bill
