Safety Wire for 2-piece Brake Rotors - Miata Turbo Forum - Boost cars, acquire cats.

Welcome to Miataturbo.net   Members
 


Suspension, Brakes, Drivetrain discuss the wondrous effects of boost and your miata...

Reply
 
 
 
LinkBack Thread Tools Search this Thread
Old 02-27-2014, 10:16 PM   #1
Supporting Vendor
Thread Starter
iTrader: (31)
 
Savington's Avatar
 
Join Date: Nov 2006
Location: Sunnyvale, CA
Posts: 14,370
Total Cats: 1,332
Default Safety Wire for 2-piece Brake Rotors

A couple of people have asked me for a step-by-step on how to quickly wire brake rotors for safety wire. The rotors here are our 11.75" Wilwood rotors, so the exact hardware on your rotor may not look the same, but the theory and some of the technique will still apply.

The goal of safety wire is to stretch a piece of wire tautly between two bolts in such a way that if either bolt were to loosen, the wire would grow more taut. Think of each bolt as a clock: if you run wire from 5o'clock on the left bolt to 10o'clock on the right bolt, both bolts can be loosened without disturbing the wire. Not good. If you wire them from 1o'clock to 7o'clock, neither bolt can be loosened. This is the most important thing to get right when you safety wire anything - if you wire in the wrong direction, you may as well not do it at all.

The only special tool you need to do safety wire is a pair of safety wire pliers. You can spend as little as $20 from Harbor Freight for a pair. You can do it with vise grips or even just a pair of needlenose, but it will take much, much longer. Buy the right tool for the job

I've drawn the orientation of the hole through the head of the bolt with a black sharpie marker so you can easily see it.

I start by deciding on the path of the wire. In some cases, I'll be able to run directly from the 1 or 2 o'clock position to the 7-8o'clock position. Sometimes I'll need to start as far away as the 10 o'clock position on the left and wrap the wire all the way around to the 4 o'clock position on the right in order to maintain the correct wire path between the two bolts. In this case, I've chosen a fairly easy one just to demonstrate the technique. I'll show a more complex one later on.

I size the wire by threading through the backside of the hole I want to come out, routing along the appropriate wire path, and then laying it over the top of the bolt I'll be finishing on. Give yourself at least two extra inches beyond the end of the second bolt - more wire is better, but don't leave too much or it will get in the way when you twist the wire using the safety wire pliers.



I then match the other side of the wire to this length. It's important to wrap the wire around the top side of the left bolt.





Clamp the wire at the intersection between the hole and the wire at approximately a right angle. You can err slightly on the short side, but don't go too short or you'll end up with an unattractive untwisted portion between the two bolts.



Once you've clamped, and you're sure the wire is routed over the top of the left-side bolt, give several twists on the pliers. My pliers typically get 7-8 twists between bolts, depending on the length of wire I'm twisting.



Separate the two ends of the wire and route whichever wire is on top through the hole. Route the wire on the bottom around the bottom of the right-hand bolt.





Clamp the wire about 1" past the end of the second bolt, and twist the wire backwards or counterclockwise. High-end safety wire pliers are reversible, but you can do this short portion by hand pretty easily with a cheap pair of pliers. The backward twist ensures that the wire stays wrapped around the bottom of the second bolt, instead of being rolled over onto the top side as the wire is twisted up.





Clip the excess wires, leaving around 1" left. Grab it about 2/3 of the way away from the bolt, then fold the short portion over the top of the long portion. This keeps the sharp edge of the wire away from your hands while you're installing the rotor, and it just looks pretty.





And we're done! Only 7 more pairs to go!



Here's a more complex example. In this pair, the two bolts don't provide as clear a path from the top left to the bottom right. In this case, I'll start at the 11o'clock position and wrap down and around to the 5o'clock position.



Here you can see where I clamp the wire for this example - right at the intersection between the hole and the wire.



Here's the final path with the first twist done (it's upside down now)



Hopefully this is helpful to those of you who are swapping your own rotor rings. If this looks wildly complex or over your head, no need to worry - for Trackspeed customers, just cut the old wire off and ship your hats and bolts back to me and I'll install new rings and wire on your hats for $100 per pair (including rotors).
Attached Thumbnails
Safety Wire for 2-piece Brake Rotors-m8agdal.jpg   Safety Wire for 2-piece Brake Rotors-4gnp0wm.jpg   Safety Wire for 2-piece Brake Rotors-ncxgbys.jpg   Safety Wire for 2-piece Brake Rotors-tkciorz.jpg   Safety Wire for 2-piece Brake Rotors-jt7fzcw.jpg  

Safety Wire for 2-piece Brake Rotors-n6aifce.jpg   Safety Wire for 2-piece Brake Rotors-peouod7.jpg   Safety Wire for 2-piece Brake Rotors-dzy2e41.jpg   Safety Wire for 2-piece Brake Rotors-7g4tss5.jpg   Safety Wire for 2-piece Brake Rotors-uvbj58e.jpg  

Safety Wire for 2-piece Brake Rotors-f0y0vyz.jpg   Safety Wire for 2-piece Brake Rotors-i8wdwas.jpg   Safety Wire for 2-piece Brake Rotors-tsdyumc.jpg   Safety Wire for 2-piece Brake Rotors-liwbund.jpg   Safety Wire for 2-piece Brake Rotors-nmjd7qi.jpg  

Savington is offline   Reply With Quote
Old 02-27-2014, 11:21 PM   #2
Destroyer of Inconel
iTrader: (37)
 
EO2K's Avatar
 
Join Date: Apr 2010
Location: In ur driveway, abusin' ur WPA
Posts: 9,642
Total Cats: 954
Default

OK, this is awesome, thank you for the walkthrough with pics!

Could you possibly speak to the various materials for wires and fasteners? Also the relationship between hole size and wire size? Im thinking this might benifit those of us who are planning to do something silly like drill stock chra to turbine housing bolts for safety wire.

I regret I have but one prop to give for this post. Feels a bit sticky
EO2K is offline   Reply With Quote
Old 02-28-2014, 12:05 AM   #3
Supporting Vendor
Thread Starter
iTrader: (31)
 
Savington's Avatar
 
Join Date: Nov 2006
Location: Sunnyvale, CA
Posts: 14,370
Total Cats: 1,332
Default

Wire is 304SS 0.032". 0.028" is available and easier to work with, so long as you don't break it by wrapping it too tight. Available at any motorcycle supply shop (Cycle Gear, etc). Fasteners come with our kit
Savington is offline   Reply With Quote
Old 02-28-2014, 12:28 AM   #4
Elite Member
iTrader: (1)
 
Leafy's Avatar
 
Join Date: Jun 2012
Location: NH
Posts: 9,093
Total Cats: 90
Default

Quote:
Originally Posted by EO2K View Post
OK, this is awesome, thank you for the walkthrough with pics!

Could you possibly speak to the various materials for wires and fasteners? Also the relationship between hole size and wire size? Im thinking this might benifit those of us who are planning to do something silly like drill stock chra to turbine housing bolts for safety wire.

I regret I have but one prop to give for this post. Feels a bit sticky
Buy the bolts. $20 for 4 bolts is better than $15 on drill bits, 3 hours of your time, and the brain aneurysm you're going to wish you had rather than trying to drill the bolts. Especially if you dont have a drill press.
Leafy is offline   Reply With Quote
Old 02-28-2014, 02:00 AM   #5
Senior Member
iTrader: (1)
 
Join Date: Mar 2010
Location: Bay Area, CA
Posts: 695
Total Cats: 140
Default

Agreed about the props for a great post, I had the general idea before but this makes it very clear.
gesso is offline   Reply With Quote
Old 02-28-2014, 02:38 AM   #6
Senior Member
iTrader: (1)
 
Join Date: Dec 2010
Location: Farmington Hills, MI
Posts: 878
Total Cats: 93
Default

Safety wire is awesome, it really builds character when you have to safety wire bolts in very tight spaces.
acedeuce802 is online now   Reply With Quote
Old 02-28-2014, 12:44 PM   #7
Destroyer of Inconel
iTrader: (37)
 
EO2K's Avatar
 
Join Date: Apr 2010
Location: In ur driveway, abusin' ur WPA
Posts: 9,642
Total Cats: 954
Default

Quote:
Originally Posted by Leafy View Post
Buy the bolts. $20 for 4 bolts is better than $15 on drill bits, 3 hours of your time, and the brain aneurysm you're going to wish you had rather than trying to drill the bolts. Especially if you dont have a drill press.
Already have bolts, drill press, 12 pack of cobalt 0.040" drills & brain aneurysm. Sounds like all I'm missing is some wire and a pair of nifty pliers
EO2K is offline   Reply With Quote
Old 02-28-2014, 12:52 PM   #8
Supporting Vendor
Thread Starter
iTrader: (31)
 
Savington's Avatar
 
Join Date: Nov 2006
Location: Sunnyvale, CA
Posts: 14,370
Total Cats: 1,332
Default

Savington is offline   Reply With Quote
Old 02-28-2014, 12:59 PM   #9
Elite Member
iTrader: (1)
 
Leafy's Avatar
 
Join Date: Jun 2012
Location: NH
Posts: 9,093
Total Cats: 90
Default

Quote:
Originally Posted by EO2K View Post
Already have bolts, drill press, 12 pack of cobalt 0.040" drills & brain aneurysm. Sounds like all I'm missing is some wire and a pair of nifty pliers
Leafy is offline   Reply With Quote
Old 02-28-2014, 01:40 PM   #10
Elite Member
 
Join Date: Oct 2011
Location: OKC, OK
Posts: 2,659
Total Cats: 76
Default

Quote:
Originally Posted by Savington View Post
Thanks for the link. Now I need to go back and look up the specs on the 11" kit to see if something works.

I'd feel better with them safety wired vs the Loctite button head screws that come with the kit.

Which Resbond formula do you use?
z31maniac is offline   Reply With Quote
Old 02-28-2014, 01:41 PM   #11
Supporting Vendor
Thread Starter
iTrader: (31)
 
Savington's Avatar
 
Join Date: Nov 2006
Location: Sunnyvale, CA
Posts: 14,370
Total Cats: 1,332
Default

907TS
Savington is offline   Reply With Quote
Old 03-02-2014, 02:02 PM   #12
Junior Member
iTrader: (1)
 
Join Date: Sep 2009
Location: Colorado
Posts: 166
Total Cats: 5
Default

after years and many cans of safety wire, this makes like much easier. https://www.dmctools.com/Products/safe-t-cable.html
GraemeD is offline   Reply With Quote
Old 03-02-2014, 02:36 PM   #13
Elite Member
iTrader: (12)
 
Join Date: Sep 2007
Location: Charlotte, NC
Posts: 6,868
Total Cats: 66
Default

I bought safety wire and a safety-wire tool from Harbor Freight. Worked perfectly.

If you've never used safety wire pliers, here is an excellent demonstration...

Doppelgänger is offline   Reply With Quote
Old 03-03-2014, 08:39 PM   #14
Junior Member
iTrader: (3)
 
Join Date: Apr 2010
Location: South Bay, CA
Posts: 354
Total Cats: -2
Default

How hard would it be to make a list for something like "these are the parts you should safety wire when going racing"?
comradefks is offline   Reply With Quote
Old 03-04-2014, 12:52 AM   #15
Senior Member
iTrader: (1)
 
Join Date: Dec 2010
Location: Farmington Hills, MI
Posts: 878
Total Cats: 93
Default

Quote:
Originally Posted by comradefks View Post
How hard would it be to make a list for something like "these are the parts you should safety wire when going racing"?
I'm not so sure about the common failure parts of hard tracked Miatas, but in FSAE we have a general rule of failures. If something breaks, does the vehicle roll to a stop, skid to a stop, or come to a screeching halt? If it's either of the latter two, it's a critical fastener and it needs some kind of positive lock. Whether that be safety wire, nylock nut (or some kind of self locking nut), or thread locker. Well, thread locker isn't acceptable for FSAE, but as long as it's not in a high heat area, it's good for me.
acedeuce802 is online now   Reply With Quote
Old 03-04-2014, 03:40 AM   #16
Junior Member
 
Join Date: Jan 2011
Location: Winnipeg, Canada
Posts: 84
Total Cats: 1
Default

this is pretty cool, ive actually witnessed one of these 2pc rotors fail, so it could save you money in the end



Attached Thumbnails
Safety Wire for 2-piece Brake Rotors-lktjq9z.jpg  
ACiFiC is offline   Reply With Quote
Old 03-04-2014, 07:26 AM   #17
Elite Member
iTrader: (6)
 
Join Date: Sep 2007
Location: CA
Posts: 1,990
Total Cats: 9
Default

Nice write up, Sav. Thanks.

I know you mentioned the reverse twist (I can see that helping), but I still can't see how that completely prevents the wire from slipping over the smooth side to the top of the bolt, effectively making the wire not taut anymore. I know it works, just wondering if it ever slips with so little friction.
kenzo42 is offline   Reply With Quote
Old 03-05-2014, 05:37 PM   #18
Junior Member
 
Join Date: Feb 2012
Location: Quebec city, Canada
Posts: 122
Total Cats: 1
Default

Did a LOT of safety wire in fsae, and trust me, when it is done correctly, it won't slip over.

Ben
bigben is offline   Reply With Quote
Old 03-06-2014, 01:46 PM   #19
Senior Member
iTrader: (6)
 
Join Date: Jun 2010
Location: San Rafael, CA
Posts: 1,125
Total Cats: 41
Default

After seeing one of these bolts back out on a forum members car I was sold on the concept. It's not that hard to do and if you struggle with it stop by a motorcycle shop and have them do it for you. Work the piece on mind for sure.

Great write up Sav!
k24madness is offline   Reply With Quote
Old 03-13-2014, 10:16 AM   #20
Senior Member
iTrader: (8)
 
Join Date: Oct 2010
Posts: 581
Total Cats: 4
Default

Quote:
Originally Posted by GraemeD View Post
after years and many cans of safety wire, this makes like much easier. https://www.dmctools.com/Products/safe-t-cable.html
Where did you get those from? Seems perfect!
joyrider is offline   Reply With Quote
 
 
Reply

Related Topics
Thread Thread Starter Forum Replies Last Post
Project Gemini - Turbo Civic on the Cheap Full_Tilt_Boogie Build Threads 59 Yesterday 09:00 PM
1994 Spec Miata Race Car SM/SM2/SSM For Sale Quinn Cars for sale/trade 6 10-23-2016 08:58 AM
My solution for Oiltemp and Oilpressure input into Megasuirt (MS3) Zaphod MEGAsquirt 41 01-24-2016 01:25 PM
Leaky Wilwoods mx592 Suspension, Brakes, Drivetrain 1 10-01-2015 01:45 AM
wiring wideband ground to battery terminal btabor ECUs and Tuning 10 09-28-2015 06:33 PM


Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



All times are GMT -4. The time now is 10:49 PM.