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Speed - July, '07 > Tech Feature

Apex Composite Rotors

 

Given the vast amount of science and technology that goes into producing our Apex composite rotors and brake pads, I would like to take the first opportunity to clarify that I am neither scientist nor metallurgist. With that being said, I will attempt to describe in layman terms the materials and processes used to produce the world class, MOTO G.P. quality brake rotors we have most recently introduced to the V-Twin market segment.

METAL MATRIX COMPOSITE: A type of composite material with at least two constituent parts. One being a metal. The other material may be a different metal or another material such as a ceramic or organic compound. In our case aluminum alloy and ceramic particles are used. The MMC ingot is cast using the highly patented process developed by Swan Composite INc. What is unique about the casting process, is that it allows for very tight control over the ceramic particle disspersment throughout the entire band width of the friction ring. In other words the disks are functionally gradient. 50% of the ceramic by volume is concentrated at the outer most portion of the friction ring, where it will see the highest temperature, while only 15% of the ceramic by volume is concentrated at the inner most portion of the friction ring, where it will see lower temperature. This effectively balances the internal stresses caused by the difference in temperature between the inner and outer most portion of the friction ring {see exhibit "A"} Now that we have a vague overview of this amazing technology, let us consider the application.

MOTOR CYCLE BRAKE: A brake is a device for slowing or stopping the motion of a machine or vehicle. The kinetic energy lost by the moving part is usually translated to heat through friction. Note that the kinetic energy increases with the square of the velocity {E = M V2 relationship}. This means that if the speed of the vehicle doubles, it has four times as much energy. The brakes therefore dissipate four times as much energy to stop it, and consequently the braking distance is four times as long.

We do not claim to be able to change the laws of physics, but through careful consideration of the application, available materials, and proven manufacturing processes, we claim to mitigate to some degree the negative effects the law of physics may have on a fast moving motorcycle. {see exhibit "B"}





American Motorcycle Dealer - August, '07 > Product Review

Out Braking the Competition
Lyndall Racing Brakes LLC
800.400.9490
www.lyndallracingbrakes.com

Written by Duncan More
Interview & Photography by Chris McGee
 

Lyndall RAcing Brakes, which began with club level racer Paul Kitrell trying to improve the brakes on his race bike, is a leading supplier of high-performance pads and rotors for all models of Harley-Davidsons. Chris McGee discovers what it takes to out-brake the competition.

Paul Kitrell and Arianna Orner are the couple behind Lyndall Racing Brakes (LRB), which is now celebrating its tenth year in business, but the story of the company began long before that.

In 1996 Paul was a club level racer riding 600cc sportbikes at Willow Springs, while working for a company which supplied brake components to various automotive racing teams, including those competing in Formula Atlantic and Indy Light open wheel car racing. However, the technology used on the bikes didn't match what he saw being used on the cars. "As a racer at club level I was unimpressed with the brake pads available compared with their car equivalents. They had carbon-Kevlar with trace iron compound pads, which were really effective," he says.

His answer to the problem was to start hand-cutting his own brake pads using pad material purchased from his employer. Word spread around the pits about what he was doing, and his work was soon in demand from fellow racers.

It was at this point that he made a direct approach, with his boss's approval, to the supplier who provided the compound for the pads used by his employer in the race car brake pads. This led to him working with the supplier on developing a new compound designed specifically to meet the needs of motorcycle riders. The next stage of the development work was a compound specifically for use with stainless steel brake rotors.

Within two years of cutting his first pads, Paul was in a position where he had to make a decision about his future; remain an employee or go it alone. The decision he made was to approach his parents, and with their help established Lyndall Racing Brakes. Paul says: "My dad's background was in manufacturing with an emphasis on sales and marketing. He had always been supportive, and now that he was retired he had time on his hands, so he was able to help me alot when we started." That was in 1998 with a line of sport bike brake pads, and by 1999 LRB had begun supplying local Harley-Davidson dealerships with a line of replacement pads for those too.

Such has been the success of the company that today authorized H-D dealerships from San Marino to San Diego only stock two types of brake pad: OE or Lyndall. An impressive statistic given that dealers receive loyalty points for all OE equipment they sell. Paul puts this success down to the effectiveness of the pads claiming 30 percent stopping power over stock items. Other claimed benefits include no brake dust and no damage to the rotors.

Lyndall racing brakes are available in three different compounds: Gold, Z-Plus and Red-Plus. The Gold compound is the company's original pad derived from Formula Atlantic and Indy Light open wheel car racing. The friction material is a proprietary blend of carbon-Kevlar and trace iron, which LRB claims excels in extreme environments and after a break-in period generally averages about 7,000 to 10,000 miles. The Z-Plus compound is a softened version of the Gold compound and as such does not require the break-in period. It is recommended for general purpose riding and offers a high coefficient of friction, and is claimed to be the most rotor friendly pad in the industry; producing no dust, no rotor wear, and no noise. The final compound available is the Red-Plus, specifically designed to complement metal matrix composite rotors. LRB says it provides the highest coefficient of friction, the longest service life, and runs cleaner and quieter than any other composite-specific pad available.

Given that Lyndall Racing Brakes supplies pads for use with composite rotors, it should come as no surprise that is also supplies such discs. Called Apex Performance Rotors, they are made of an allow of 80 percent aluminum and 20 percent silicon carbide. The way in which they are manufactured differs from other rotors, in that they are spun cast. The benefit of this manufacturing process is that it places the maximum ceramic content at the outer edge of the rotor; the area most affected by heat build-up. Arianna Orner, Paul's partner and company CFO, explains the benefits of the LRB Apex rotors: "Some ceramic rotors have problems with the surface cracking but our manufacturing process avoids this issue. That's not to say we haven't had failures in the past, but we've learnt from them.

In addition to the claimed performance benefits of the replacement discs they also have the advantage of reducing the unsprung mass on a bike's front end. A standard OEM disc weighs 3.8lb, whereas a LRB Apex disc, which is a fully floating design, is just 1.6lb. Due to the modular construction of the disc, parts are interchangeable, giving people the choice of carrier color and the ability to swap from ceramic to stainless rotors of vice versa. Seventy series aluminum fittings are also used throughout for the fitting on the discs.

The current line-up of Lyndall Racing Brakes' Apex and stainless brake discs includes applications for all Harley-Davidson models, including V-Rods and Buell, as well as American IronHorse, Big Dog and Victory. The discs are also compatible with Performance Machine, Brembo, JayBrake and HHI aftermarket applications.

Paul is so confident of the product Lyndall Racing Brakes supplies that he says: "If a customer isn't satisfied with the product, I'll buy it back from him. When a customer comes to us he doesn't buy a brake product, he buys a brake company!"

Download Our Brochure:
Apex Performance Braking