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BMW 3-Series (E90 E92) Forum > BMW E90/E92/E93 3-series General Forums > Regional Forums > Canada > Finished my brake rotor machining setup



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      08-18-2018, 06:38 PM   #1
Nick.B
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Finished my brake rotor machining setup

With 3 of these cars all using expensive brake rotors, and two of them with thick, but pulsating rotors, I've been working on a setup for the milling machine in my garage for turning the rotors. I finally got the last piece done and cut a pair of rotors today.

Like the phrase when all you have is a hammer, everything is a nail, when all you have is a vertical milling machine, every lathe job gets done on the inverted vertical spindle lathe.

It's nice to have smooth brakes again.
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      08-20-2018, 08:17 AM   #2
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Taking appointments? Lol

Brakes are fine but stupid vibrations are annoying (and confirmed from rotors)
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      08-20-2018, 03:08 PM   #3
fredcase
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Yikes. So long spindle bearings.
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      08-21-2018, 05:12 AM   #4
Nick.B
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Originally Posted by fredcase View Post
Yikes. So long spindle bearings.
I hadn't considered that. I knew it wouldn't be a rigid setup and speeds/feeds would have to be kept quite low to avoid chatter.

It's running around 50rpm, .002-.005 depth of cut, .005-.008 per rev feed.
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      08-21-2018, 07:32 AM   #5
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This would be cool to have in a dream garage, but in reality who's got the space.

My solution for vibrating / warp-prone rotors: cryogenically treated, high-carbon rotors. Tried it on my truck and it's solved my problem for the past 2 years. Granted, they are more expensive than cheap offshore made rotors (actually, I think my cryo rotors were made offshore!), but to me it's been well worth it. And I use no garage space
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      08-21-2018, 06:58 PM   #6
fredcase
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Quote:
Originally Posted by Nick.B View Post
I hadn't considered that. I knew it wouldn't be a rigid setup and speeds/feeds would have to be kept quite low to avoid chatter.

It's running around 50rpm, .002-.005 depth of cut, .005-.008 per rev feed.
The leverage against the bearings that far away from center.
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      08-23-2018, 06:42 AM   #7
Nick.B
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Quote:
Originally Posted by kenmar View Post
This would be cool to have in a dream garage, but in reality who's got the space.
The mill is already in the garage taking it's space and being used fairly often for other jobs.

Quote:
Originally Posted by fredcase View Post
The leverage against the bearings that far away from center.
Yeah, I understand the leverage, which is why I keep the cuts relatively light. I don't think the spindle bearings are in top shape to begin with. I got the machine used from a railway maintenance shop for $400, so I can't really complain.
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      08-23-2018, 01:47 PM   #8
fredcase
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Quote:
Originally Posted by Nick.B View Post
The mill is already in the garage taking it's space and being used fairly often for other jobs.



Yeah, I understand the leverage, which is why I keep the cuts relatively light. I don't think the spindle bearings are in top shape to begin with. I got the machine used from a railway maintenance shop for $400, so I can't really complain.
$400? what a steal.

Bearings aren't even that hard to swap on those anyways.

Easier than an x-drive oil pan.

Ask me how I know.
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      08-24-2018, 07:08 AM   #9
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Quote:
Originally Posted by fredcase View Post
Bearings aren't even that hard to swap on those anyways.

Easier than an x-drive oil pan.

Ask me how I know.
I had the spindle out of the quill last year. Spun smooth, with some drag suggesting light preload. Nothing FELT wrong with it.

I've done a RWD pan gasket. Have to do the wife's soon too. Glad I don't have that axle and transfer case to deal with.
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