Eric,

If your rust in on the inside surface only, then I suspect your pads
are not in contact with your rotors. Check your calipers. Regardless
of rate of oxidation of your rotors, a properly maintained braking
system should have equally pressure on either side of your rotor. I've
had completely rusty rotors cleaned by the pads in a two mile stop and
go drive.

BenT

On Mon, 16 Aug 2004 14:31:00 -0400, Eric Zeno <vw4x4@fyi.net> wrote:
> I guess I'm not getting my question out just right here.
> Has anyone had severe rust on new syncro rotors after
> say 2 years, or so, so bad that they are junk?   I have,  and
> there is clear evidence that the materials in these rotors are poor
> quality, This is just  like what we have experienced with brake
> in the early days.  Anyone want to see a picture?  I just check
> my records.  These brake do have about 25,000 miles on them.
> Pads are about half warn down.  That is average for me.
> Very good for this area.   Most people can not get 20,000
> out of any brakes in Pgh.
>   My dad had a Honda accord.  Every 8000 miles the brake
> were into the rotors.  This was a poor design as a friend had
> the same problem.  THis is clearly not the case with the
> syncro.   I'm looking for other subjust to compare notes.
>                                       Eric
>
>
>
>
> Karl Wolz wrote:
>
> >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
> >
> >
> >
> >
> >
>

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