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Subject:Re: Syncro front rotor life expectance
From:Karl Wolz
Date:Mon, 16 Aug 2004 11:12:12 -0700

Eric,

From what I've read in this thread, it sounds like your complaint is
that the rotors are rusty - not that they are worn (my apologies if I've
misinterpreted your posts).

Rotors are made of iron, which in practical use is always an alloy -
different elements are added to the iron to achieve hardness, etc.  Iron
rusts when it gets wet.  No way around that.  Your salty roads should
increase that problem.

Being heated (normal for brake rotors) accelerates the rusting - that's
simple physics.  I've used rotors that were quite rusty.  The first time
you hit the brakes, most of the rust is swept away.

It would be pretty difficult to predict how long a pair of rotors will
last, not knowing the answers to questions like, "what kind of pads do
you use", "are your calipers in good shape", "do you tend to park in the
ocean" ;-), etc.

If the rotors are truly worn out (you've checked them with a
micrometer), then I'd say that something is wrong (see above ideas).  To
say that a list vendor is to blame is probably a bad call.  Any list
vendor that I've dealt with has delivered top quality merchandise every
time.  Any manufacturer can deliver a defective product (though I don't
see how with a rotor), but to suggest that any vendor would deliberately
supply second rate rotors is pretty harsh.

If you haven't measured the thickness of your rotors, do so, and let us
know how worn they really are.  A bit of rust is normal, and should
clean off with the first application of your brakes.

Karl Wolz