Rivetless disc machining

[RIPPERTON]

After much development, Ripperton Design has finally achieved a system for machining Motorcycle Brake Discs without removing and replacing the standard rivet.
A recessed magnetised face plate for mounting the disc securely and tool post grinding arrangement for facing the disc. A coarse diamond grinding wheel will be fitted to the grinder to replace the stone. Testing will proceed with the CBR discs shortly. Here are some 98R1 discs with 75,000km service.
Before
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00062.jpg

After
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00061.jpg

[wade193]

Looks good. How much time do you think it would save doing it your way?

[RIPPERTON]

Looks good. How much time do you think it would save doing it your way?

Half hour. I was talking to the bloke down in Vic who machines discs with rivet removal. Forgot how much he charges but he supplies new rivets. Gonna have to find his number.
This system is also good for unparrallel or bumpy discs that arnt necessarily worn out. Some after market or "bling" discs are bumpy straight out of the box.
The GIX600 that I rode in the Wakefield 4 hour relay had freekin atrocious front brakes. The supposed new after market discs vibrated at speed and the lever almost came into the bars at times. Ill be having a go at those discs soon.

[Naked Twin]

How many times could you machine the disk and still have them as usable or legal?

Just wondering what the consensus is as I was told bike disks are not as easy to machine as a car disk, I was told to through them away (I sold the whole bike instead).

Nick

[RIPPERTON]

Static results. 98 R1 brake disc
Original thickness 5.000mm (300mm dia)
minimum thickness according to Yamaha manual 4.500mm
Finished thickness global 4.585mm
Thickness removed by grinding 0.415mm
Thickness deviation after grinding measured at 10 points around the pad track. 0.005mm. (thats flat !)
After already done 75,000km I would confidently run these discs another 50,000km to slightly under the minimun thickness limit before binning them.
Just got to figure out what thats worth, economy v labour.
Off hand I would charge at least $40 -$60 per disc depending on time taken. Older discs take more time to get rid of the lips, but newer discs that are bumpy due to crash damage or thermal shock would take less time
Anyone with an early R1 that would like to test a pair of discs, contact me on 0424 479 391

Edit: second disc turned out similar. 4.570mm and 0.005 thickness deviation.

[Marcus]

I was going to ask if you can machine a stock 06 r6 rear disc. I was considering taking a drill bit and counter sink to it...

[RIPPERTON]

I was going to ask if you can machine a stock 06 r6 rear disc. I was considering taking a drill bit and counter sink to it...

Cant do rears yet as have to make a whole new face plate but will let you know when I have it set up.
Erm whats the drill and countersink do?? I hesitate to ask

[Marcus]

hopefully taking some mass off it but mainly trying to reducing the bite

[RIPPERTON]

CBR discs and pads were also ground and was able to test the finish on track.
Absolutely perfect brakes. I could punch them as hard as I wanted till the rear lifted and Ive never felt anything so smooth. Also the rear Brembo that I fitted is both more powerfull and has shorter stroke. I am supermotard brake sliding into t9 with the back stepping out a little and my hand brake rear works better too.

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00068.jpg

[Jungleboy]

Good work mate, I can see this comming in handy for a few racers out there!

[RIPPERTON]

First customer, :mod_smilie_rockwoot heres AZNOZ's 03 R6 front disc that I suspect has had some disc lock trauma.
The left disc has a localized sunken section that was about 0.05 deep and caused a harsh knocking in the brakes.
The bent disc came out to 0.007mm flatness and the other good disc which had to be ground as well came out to a new Rip record of 0.001mm flatness. On the road the brakes felt very smooth and solid. $150...bargain :ayyy:
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00088.jpg

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00089.jpg

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00090.jpg

http://i37.photobucket.com/albums/e62/ripperton_2008/aznozleft.jpg

http://i37.photobucket.com/albums/e62/ripperton_2008/aznozright.jpg

[dazzler]

well Rip one of these days, when we finally meet, i may get you to inspect my discs, i am not aware of any issues with them.

but then again i have no fucken idea as to what to look for and also what i am feeling for!!

[RIPPERTON]

Theres probly nothing wrong with them if you arnt aware of anything.
Aznoz's brakes were so bad I didnt even get out of my street before turning around and heading for the garage.
But Il give it a test ride if you want. :ayyy:

[Zee]

Nice work there Rip...so precise (0.001) and in tolerance :clap:

Ya need to place an add in the bike mags or formula extreme at the least :ayyy:

[aznoz]

Thanks again champ :ayyy:

Brakes are brilliant! Held up very well today at EC. No more shuddering, just a nice, smooth, consistent feel. Couldn't be happier.

If anyone is thinking of getting discs machined or even replaced due to warping or whatever, give Ripp a go. I was gonna buy a new set of discs (what are they like $8-900?) cos i thought they were so bad (Ripp knows how bad they were) and in the end walked away only $150 outta pocket!!!

[RIPPERTON]

Thanks again champ :ayyy:



Good to hear
Thanks for the write up :ayyy: