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Old 12-08-2006, 08:17 AM   #1
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Default CORVETTE: RB's Brake Design and Development Philosphy

This reply was posted to Corvette forum on 12-08-2006 under this thread:
Racing Brake's stock replacement two-piece rotors


You may wonder why RB being a relatively unknown company in Corvette community would make more two piece rotors and OE caliper kits than those well known brands. It is because our brakes are built based on the following principles:
  1. Safety: Our rear brake upgrade always retain the OE?s emergency brakes i.e., If it has drum brake we make our two piece rotors with ?iron hat" instead of aluminum hats like those name brands (Al melting temp is ~1220*F while Iron is ~2800*F)
    If OE has caliper activated E-brake, then we make longer one piece bracket along with the big rotor to retain the E-brake function. (Click to learn more...http://www.racingbrake.com/main/oe_c..._brake_kit.asp)
  2. Integrity: When we build front BBK we also make compatible rear BBK to go with the front (Both are released at the same time) to maintain the same proportion in brake duty distribution as OE. A true balance brake can only be achieved by a good design with proportional brake rotor sizes for front and rear like original car manufacturers. We have customers installed those name brand front BBK either buying our rear BBK or requesting us to develop the compatible rear BBK which are not available from those name brands who offer the front BBK. (see our new development forum...)
  3. Cost Effect: For someone who has deep pocket and like big names this is no an issue but for most of us we all want to spend money only as needed without overkill. When a customer asks for brake upgrade we always suggest to replace a better pads first, if not good enough replace rotors. Most of the upgrades don?t require anything more than a rotor and pad upgrade. We have been providing our two piece rotors with true racing pads to World Challenge and Grand AM cup racers who raced with OE calipers w/o any issue. Our brake upgrade is aimed to retain OE calipers, so that customers can save money and with freedom of choice on aftermarket pads. Although we just learned that this may not be the case for Z06 due to short of good aftermarket pads (pad is too thin and no wear sensors) and the caliper pin is hard to reinstall when replacing pads which we have been working on these issues (including convinced Hawk to make racing compound DTC-70. DTC-60 available) and will annouce our solution soon.
If after pad and rotor upgrades, the OE caliper setup is still not good enough for some more serious racers, we will also have solution to that. Our caliper set up will have both front and rear and will retain the use of stock rotors (any upgraded rotor remain useful), so you investment will be on incremental and as needed basis which we believe is what a brake upgrade is supposed to be.

We would appreciate your comments and look forward to serving your brake needs.
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Old 02-13-2007, 08:26 AM   #2
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Quote:
When I motorcycle roadraced my Ducati I used 13 inch full floating Brembo cast iron rotors on aluminum carriers. Bike was making 120+rwhp and weight was 400# with 150# for me. The rotors were covered with holes and never had any problems.

I have noticed that many people are strongly against holes in car rotors. What is the problem? Is it a weight induced cracking issue?
http://forums.corvetteforum.com/show...post1558933516

Very good question. To our knowledge most motorcycles rotors are made of 400 series stainless steel, the disc is hardened (for wear resistant) and mirror polished (for the look). Stainless steel has good strength but has very poor heat dissipation and dumping capacity due to its very low carbon contents (less than 0.2%). A lot of holes are added to the discs mainly to increase the biting edges (friction) and cooling surface than for weight saving. Some mfgrs use ductile iron which is a better material for heat handling and stronger than gray iron but it?s subject to rust and therefore are not acceptable to most mfgrs and users.

So the ideal brake material for motorcycles is to have good strength and will not rust. We made discs for a major custom motorcycle mfgr with Compacted Graphite Iron (CGI) with excellent balance of heat handling and strength but as a nature of iron the surface still would rust so this project was not further pursued, while our CGI rotors made for SCCA club racing have won a great success. As far as we know RB is the first and only brake company that makes the motorsports rotors with CGI material.

Carbon (graphite) is the most essential element in cast iron casting not only by percentage like other metals, but by the type of graphite (I-VII), and out of type VII (flake graphite) it?s sub classified to 5 types (A-D) dealing with the flake distribution and flake size (graphite length). Mold design, casting process can affect any of these graphite formations which predominately dictates the quality of a casting. Learn more...

So when we evaluate the quality of a casting we first look at its microstructure (how graphite is formed under microscope) than any other criteria. Carbon is the known to be the best substance for heat handling. RB two piece rotors are made with higher carbon contents than standard G3000 gray iron, and we added alloys to make up the loss of strength due to the increase of carbon. RB two piece racing rotors have been proven in the race tracks to have outperformed the competition (provided the proper pads are used) and out last most major racing brake pads.

Most of the drilled rotors are made from stock blank which is meant for street driving that could be more prone to crack under severe braking however, in our opinion, it was purposely demoted by a brake company who promotes solely on slotted rotors (http://www.powerslot.com/images/deal...cked_rotor.jpg).

Look what motor companies like BMW did on M3 E46 competition rotors, Porsche, Mercedes, GM (C6 Z51 and Z06) and Brembo front two-piece rotors for Corvette Z06 they all supplied with drilled rotors. Contrary to most common belief, the crack was more attributed to how well can a rotor material handle the thermal stress than how strong (more material) is of a rotor, in other words it?s more of a heat factor than strength factor.

RB makes various disc finish available and we only present the facts with pro & cons for customers to make their own choice without bias.

All RB brakes carrying with our money back satisfaction guarantee for the performance, durability, low maintenance or replacement cost and look.
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