Sender: <marv@lancaironline.net> (Marvin Kaye)
To: lml@lancaironline.net
Date: Tue, 30 Sep 2003 14:03:32 -0400
Message-ID: <redirect-2609372@logan.com>
From: RWolf99@aol.com
Subject: Matco Brake Parts
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I just got off the phone with George Happ of Matco.  A very helpful and 
personable man who, along with his charming wife, I have spoken to at Oshkosh 
concerning the brakes on my Lancair 360.

FYI -- I picked up "Super Fast Build Kit No. 350" in February 1994.  Many 
things may have changed since then.

The standard 320/360 brake uses the "D5" disc.  This has apparently been made 
in three versions -- aluminum, steel, and a new version which is also steel.  
The new ones have the letters "D5" plainly stamped on them in letters at 
least 1/8 inch high.  On the face, not on the edge.  You can't miss it.

The aluminum ones should be replaced immediately.  George didn't actually say 
that -- he said that "they are bad in every way and have a brittle failure 
mode".  I believe this is what Ric Argente and Paul Nafziger have experienced, 
with chunks flying out of their discs and the possibility of sudden wheel 
locking when the edge of the missing segment hangs up on the brake pad.  Ouch!  It 
would be interesting for them to verify that these were not steel.  (Anyone 
got a magnet?)

The steel ones that are gold colored have some free graphite in them, and it 
is possible to have a gradual loss of braking effectiveness with those discs.  
George says this can be cured by having them plated with electroless nickel 
to a thickness of 0.001-0.002 inches.  There is apparently no risk of brake 
disc fragmentation and these are quite usable after plating.  I have these discs.

The third version, which is the version currently shipping, has "D5" stamped 
in them and are the ones to use.  I have ordered a pair of these (about $60 
each) and will be installing them this weekend.  Eventually I will have my old 
ones nickel plated -- George says they will look really cool, so why not?

On another issue, I have long planned on replacing the plated steel sliders 
(the spacers that go over the bolts) with stainless.  Fortunately, Matco has 
these available for $5 each, so I don't have to go buy a piece of tubing and 
find a lathe.  I bought a set of eight in 2002 and will be installing those this 
weekend, too.

On a final issue, many have changed pad materials to Cleveland parts.  George 
is aware of this and Matco developed an improved pad material a few years ago 
that they claim is even better than the Cleveland parts.  I bought a set of 
these -- the deal is that once you do, you can send your worn out pads to Matco 
and they will install new linings for free (you pay for the linings but not 
the installation).  I think I'll be sending my old linings to them now for 
replacing with the new material.

So in summary, I'm replacing the disc, the spacers and the linings before 
first flight.  I guess I'm retaining the caliper but not much else...

- Rob Wolf
LNC2 70%