Antique, vintage and classic BMW motorcycles:
How to re-line brake shoes
for improved stopping ability
by Craig "Vech" Vechorik of Bench Mark Works
The original molded brake linings of pre-1970 BMW motorcycles are not really up to the stopping requirements of today's traffic. While drum brakes can not be as effective as disk brakes, there is a simple, inexpensive way to make your vintage BMW stop better.
A modern brake lining can be substituted for the original, asbestos, molded brake shoes at less cost than that of the OEM linings. The modern lining
material carries a manufacture's designation of AF 232 and is 5/32 of an inch thick. You need approximately fifteen inches to do the front or rear brake of any BMW motorcycle made from 1955 to 1969 (thirty inches of brake material to do the front and the rear brakes).
To reline brake shoes you have three choices:
1) You can buy the OEM molded shoes and the copper rivets from BMW at a higher cost and fight with setting the rivets (which requires a succession of
specially shaped punch dies to obtain a proper seating).
2) You can buy the AF 232 and copper pop rivets from Bench Mark Works and follow my simple how-to instructions and do the job yourself.
3) You can send your brake shoes to me and I'll do the job for you. (Order information at the bottom of this page.)
AF 232 Brake lining installation instructions:
The AF 232 lining is very easy to apply, cuts easily and has a higher
friction coefficient than the original linings. You will use copper pop rivets and a hand pop riveter to secure the lining to the brake
shoes. You also need a countersink tool which I'll tell you how to make.
Making the countersink tool
This is easy to make. Choose a dull, 1/4 inch drill bit. Wear eye
protection! Use a bench grinder to grind the pointed tip off the bit. You
want to shape the end of the bit like an end mill (as close to flat as you
can get it by grinding). Use water to quench the bit during grinding so you
don't overheat the bit which will cause the metal to lose tempter. After
you have ground the end the bit flat, turn the bit around and grind the
sides of the shank into a square shape so your T-handle tap wrench will be
able to firmly hold the modified drill bit in its jaws.
Clamp your brake shoe in the jaws of a vise and use a metal scribe
to scratch a line at each end of the old lining. These scribe marks will
provide a reference point for when you measure how much AF 232 shoe
material to cut.
 | Use an 1/8-inch diameter drill bit and a hand drill to drill out the old
copper rivets from the lining side of the brake shoe. Take care that you hold the drill at the correct angle so the bit follows the rivet and doesn't wander off onto the aluminum part of the shoe. When all the rivets are out, the old shoe material falls right off. |
Thoroughly clean the aluminum brake shoe and take particular care that the
area covered by shoe material has nothing stuck to it that interferes with
the new lining.
Lay the AF 232 on the cleaned brake shoe, and line end up with one of the
scribe marks that you made on the aluminum shoe before you removed the old
liner. Temporarily clamp the material to the shoe, using a pair of vise
grip locking pliers. Be sure and hold the material down on the curved surface, and mark the AF 232 at the second mark that is scribed on the
brake shoe, so you can make your cut at that point. Remove the vise grips,
draw a complete line across the shoe material with an ink pen, and use a
hack saw to cut the AF 232 to the desired length.
Lay the cut piece on the curved shoe, and using two pairs of vise grips,
(one on each side of the hole in center of the shoe) clamp the material near
the center of the shoe. Drill a 1/8-inch hole through the new shoe material,
starting from the back side of the aluminum shoe, through the pre-existing
hole in the aluminum shoe.
Use a single edge razor blade to trim the "fuzz" from around the edge of
the hole, where the bit emerged through the new shoe material. Then, using
the modified 1/4 drill bit that you ground off, carefully support the bit
with one hand, and center the bit over the 1/8 hole.
Use your other hand to turn the tap "T" handle in a clockwise direction,
and countersink the AF 232 to a depth approximately 1/2 to 2/3 it's total thickness.
| Start pop riveting at the center hole in the middle of the lining and work your way out to each end. This way, you insure the necessary tight fit of
the lining to the shoe. (Yep, that's a hammer at the top of the photo.) After the first rivet is set, move your vise grips further out on the shoe, while holding the shoe material down tight, and reclaim the grips, and repeat the whole drilling, countersinking and riveting operation again. |  |
 | If the shoe material is a bit wide, or you have not riveted it on perfectly
straight, don't despair. Clamp the shoe in a vise, on it's side and use a
sharp box cutter to trim off the excess shoe material. The lining should be straight and perfectly
flat against the brake shoe. |
| Note the beveled edges on the top and bottom of the old shoe material. You
must Use a bench grinder to duplicate the bevel on the new lining. That is all there is to it, how does that grab you? Don't let your bad brakes stop you from enjoying your old motorcycle. |  |
Order material online:
You can click either of the following links to order brake lining online through a secure server with your Visa, Discover, American Express or Master Card.
brake lining one wheel $20.00--brake lining
brake lining for two wheels $40.00--brake lining
accessory005B--$3.25--one set rivets copper pop 3x10 brake lining one wheel pack of 18 rivets
accessory005B--$3.25--two sets rivets copper pop 3x10 brake lining one wheel pack of 18 rivets
Send your brake shoes to Vech and he will reline them for you
Your name: _________________________________________
Your address:_______________________________________
____________________________________________________
City:_______________________________________________
State:____________________ Postal Code:_______________
Country:____________________________________________
Your email address:__________________________________
Enclosed are my brake shoes. Please re-line the brakes and return to me at a cost of $60.00 per wheel,plus return shipping (to be determined). All credit cards accepted.
Card number:___________________________________
Expiration date:_______
Name on card:__________________________________
Mail your order to:
Bench Mark Works
3400 Earles Fork Road
Sturgis, MS 39769 USA
Questions?
Contact me, Craig Vechorik email vechbmw@aol.com
3400 Earles Fork Road
Sturgis MS 39769 USA
Choose one:
Vech's homepage (you are here)
Page 2: Photos and more about Vech
Page 3: Photos and more about Vech
Restorations completed by Vech
Vech's museum and campground
The Steib Sidecar Store
Technical articles
BMW-related links
Vech's guestbook
For sale: Vech's Bargains, Inventions and Hard-to-find Parts - Complete online NEW PARTS store!
For sale: Biker Art T-shirts
Bench Mark Works
Craig Vechorik email vechbmw@aol.com
3400 Earles Fork Road
Sturgis, MS 39769 USA
Telephone/FAX: (662) 465-6444
Toll-free order line: 1-800-323-7102
Hours: Monday-Thursday 8-5, Friday 8-3 central time
Technical advice from Vech Mon-Fri 1-3 central time only from telephone: (662) 465-6444
Note Bench Mark Works site address:
http://members.aol.com/VechBMW/index.html
Designed by Elaine C. White, oelaineo@aol.com
All rights reserved.
| | | |