FLEX-HONE  

for Rotors
and Cylinders (See Below)  

UTILIZING PATENTED "FLEX-HONE" TECHNOLOGY, THIS PATENTED TOOL PRODUCES
A FACTORY STYLE, OEM CROSS-HATCH FINISH... RIGHT ON YOUR SHOP LATHE!

FACT:  The profile of your rotor, not the pad you use, is responsible for brake noise!

  • Twenty seconds of forward rotation transfers the recommended OEM circular style, "cross-hatch" pattern needed on brake rotors & flywheels.
  • Specially positioned Aluminum Oxide balls level off the spiral grooves created by brake lathe bits, the prime cause of friction induced brake noise.
  • Removes the ripped, torn and folded metal fragments formed by lathe cutting blades during the surfacing and/or truing process.
  • A net cost of only about .30¢ per brake rotor... not the typical .75¢ popular scotch pads and sanding type discs cost.
  • Honing lowers harmonic vibrations created by surface irregularities, thus reducing annoying high pitched squeal & groan after the burnish.
  • Easily produce a true Plateau Finish on the rotor.  Duplicate the professional finish many performance factories do... only without a $300,000 milling machine.
  • Forget changing sandpaper or discs every rotor... the hone lasts for months!
For Rotors and Flywheels

Does it really make a difference?

Finish #A
Before Flex-Hone®
As received, rigid honed by factory rework section.  (Photo blown up to 1000x)

The cross-hatch from first working has majority of cut in one direction with many smeared, torn, jagged and folded metal edges on surface. The smeared metal is loosely attached to surface and will be easily dislodged.  In the case of a rotor, very peaky surface profiles generate excess heat during burnish process and this produces harder,  noisier brake pads.

40 to 50u” (1.02 to 1.27um) finish.
Note: Uneven, irregular Ra measurements on chart. The heights of the peaks and valleys vary greatly, widths are not symmetrical.
Finish #B
After Flex-Hone®
Reworked with Silicon Carbide hone.  (Photo blown up to 1000x)

Uniform cross-hatch pattern, notice actual X pattern on surface. Honing creates a clean open appearance with most smeared, folded and torn metal removed. Note the excellent semi-plateaued profile on the chart, the cuts are symmetrical and lower overall. In the case of a rotor, this will reduce temperature of the burnish process and produce a pad that is not as hard.

20 to 25U” (.51 to .63 um) finish.
 Note: Surface finish roughness (Ra) of reworked piece has been reduced 50%, it's a more symmetrical wave pattern.


Note:  The proper terminology for rotor finishing is "cross-hatch" not "cross-directional".  Compare the process to re-working the cylinder walls in an engine.  When you bore a block to install new pistons and rings you "cross-hatch" the walls with a Flexhone, not scuff them with a scotch pad or piece of sandpaper.  The same is true of your brake rotors, do not use swirly discs, cookies or sand paper as they can not create the proper finish for pad burnishing.

 
How to use the "FLEX-HONE for ROTORS" tool
 

FLEX-HONE - BRAKE SQUEAL - ROTOR PREPARATION FLEX-HONE ROTOR PREPARATION FLEX-HONE ROTOR SURFACE AFTER PREPARATION

Mount the Flexhone tool in an electric hand drill.  (Only use electric, not battery or air.) Straight line is OK but a 90º right angle drill works better). Maintain speed between 800 and 1000 rpm, to produce a true "cross hatch" finish.

After cutting the brake rotor (truing process), leave it mounted in the brake lathe. Pull back your cutting blade assembly (twin cutter, etc), then spin rotor at a speed around 150 to 200 rpm. (Put on your eye protection, start drill then bring it to the lathe.)

Hold the tool at a slight angle so the bottom half of balls are slightly off the surface . Stroke the tool in towards rotor center then back out, 5 to 6 times about 4 seconds each. On the last out stroke, move tool very slowly (10 seconds) until it runs off outer edge. 


TIP:  There is no need to reverse the direction of the hone, although it can be done if desired.  Additionally it is imperative that you use an electric drill to spin the Flexhone tool.  The pattern is created by the speed of the drill (RPM), not the exerted pressure or the length of time the hone is used. 


To make the process even easier and to extend the life of the tool, we highly recommend the use of a right-angle electric drill.  The 90º angle eliminates rotational torque and makes it extremely easy to properly position and hold the tool during the procedure.   If you don't have one or can't find one, we offer an inexpensive model that does a great job. 
 
The unique, compact shape goes where standard drills can't so it fits easily on the inboard side of the lathe.  Additionally, you can stand in front of the lathe and not have to twist your arms around to the side, to control the hone's important back and forth movement.
  • Fully Shielded ball bearing construction
  • Weighs only 3.8 lbs for less hand fatigue
  • Variable speed, reversible (0-1500 RPM)
  • Easy access brushes

120 Volt, 3.2 Amps, Keyed Chuck w/ 1/16" to 3/8" capacity, Overall dimensions:  10.9" x 5.25" x 2.3"

Special GWR promotional price.....   $39.95

  

See what our customers are saying about the Flex-Hone for Rotors.


If you're looking for a cylinder re-working Flexhone
please click picture...


 

GWR SPECIALTY AUTOMOTIVE PARTS GWR Specialty Automotive Products
Copyright '96 -' 06
1(800) 266-4497
Email: sales@gwrauto.com