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  #1  
Old 4 Weeks Ago
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stylEMon stylEMon is offline
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Default Drill Out Brake Rotors? Not What You Think

Hey all, i have a nice set of drilled rotors from an FXR wheel. It's the same diameter and width as the rotors on my '95 XLH but the mounting holes are slightly too small... can i drill these out in a drill press without any issue?

**Just to be clear, the mounting holes line up perfectly. But the holes are two small.

One or two steps up will do the trick.

Thanks in advance
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  #2  
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Originally Posted by stylEMon View Post
Hey all, i have a nice set of drilled rotors from an FXR wheel. It's the same diameter and width as the rotors on my '95 XLH but the mounting holes are slightly too small... can i drill these out in a drill press without any issue?

**Just to be clear, the mounting holes line up perfectly. But the holes are two small.

One or two steps up will do the trick.

Thanks in advance
Sure, but how the drilling goes, depends on the material. If a Stainless alloy, it can be tough going as It can work harden. If you want to stay on center, try a step drill bit, at least enough to start the new size.
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  #3  
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Thanks Maxeffort
It is a stainless one for sure... was planning to use titanium bits to help with that. I'll step it up slowly and give it a go! thanks
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Thanks Maxeffort
It is a stainless one for sure... was planning to use titanium bits to help with that. I'll step it up slowly and give it a go! thanks
Use a good cutting/tapping oil, the brown smelly stuff, and make sure you keep enough pressure on the bit that it's cutting and not just spinning on the material.

Gentle pressure and letting the bit spin instead of cutting is what hardens the surface you want to be drilling. Ya gotta be making chips.
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ah! great Tomcatt! thank you! I'll chip away with the oil!
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I don't know about newer Harleys, but I drilled speed holes in an ironhead rotor and tried to do the same on a shovelhead rotor (gave up). Harley s/s brake rotor material is made of diamond-like stuff. It was more difficult to drill than anything else I've done. I drilled many holes in two Yamaha rotors using one 1/4" stainless-steel specific bit from McMaster. The one Sportster rotor took about ten.
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I don't know about newer Harleys, but I drilled speed holes in an ironhead rotor and tried to do the same on a shovelhead rotor (gave up). Harley s/s brake rotor material is made of diamond-like stuff.
There is definitely a point where you step back and reconsider what you're doing. It's a judgement call. Hit it with a drill and decide, hopefully before you've made an irrecoverable mess....
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You'll soon find out titanium bits will get burnt very quick on stainless.
I'd use carbon steel bits with lots of cutting oil and slow drill speed with very small bit increments.
Personally, I'd just buy the correct rotor.
Stainless is just like any other metal. It comes in different hardness's.
You may get into a situation where you burn the holes sideways anyway from the heat.
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Quote:
Originally Posted by Tomcatt View Post
Use a good cutting/tapping oil, the brown smelly stuff, and make sure you keep enough pressure on the bit that it's cutting and not just spinning on the material.

Gentle pressure and letting the bit spin instead of cutting is what hardens the surface you want to be drilling. Ya gotta be making chips.
I agree, slow speed, firm pressure, keep the bit cool and lubed.
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IF drilling is an issue, would EDM work?
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