Amazing Manufacturing of A Car Disk Brake Plate | 

Elsewhere in India, a team of guys are using old disc brakes to restore engine blocks.

For those who do not know metallurgy, it is an extraordinary video. It has a series of serious errors in the production of brake discs. The molding sands mixture is made as considered by the mixer, without moisture control, permeability, etc. They use cast iron from engine blocks, which is a superior gray cast iron, but it is melted at the cubilou, where they burn a lot of coal to maintain the lamellar graphite and prevent the formation of cementite. The result will be low-quality lamellar graphite cast iron brake discs. If you notice, it does not show whether they are checked dynamically or statically. A disc like this, under brutal braking, is likely to break and cause a serious accident.

индусов очень много, надеюсь они делают эти прекрасные тормоза для внутреннего рынка

Customer : What alloy do you make your brake disks from? This factory : Yes

when you go to the parts store and they tell you they have the $20 part, versus the $100 part..now you know.

Ручная работа! Каждый диск уникален! Второго такого нет ни у кого!

That's some high precision ISO-9000 stuff there. Plus or minus 1/8". Wow.

Every rotor a unique size, weight and shape! Amazing!

Watch this video before going to work and you will appreciate your job

It is impossible not to appreciate the ingenuity and simplicity of the process and at the same time the incredible set of skills required to accomplish this job with basic tools. On the other hand I would never, NEVER drive a car with those brakes faster than 30km/h.

Suddenly my life seems a lot better than before

На этом предприятии прогресс по охране труда. У рабочего на сверлильном станке есть перчатки!

After over 60 years in engineering, it took this video to show me that not only have I been wearing the wrong shoes...I have also been worrying too much about the detail.

"I just got promoted from broken engine slammer to barefoot sand stomper.. so I got that going for me, which is nice."

Hats off to these guys because they are hard workers!

I was wondering how they removed the cylinder walls from the engine blocks. They did a 200IQ move and removed the engine block from the cylinder walls. Also those guys destroying the engine blocks, they must have 0% anger in them

A rare glimpse into the Autozone factory

Right out of the stone age, aftermarket rotors for the Flinstone car

Скупой платит дважды. Тупой трижды! Посадочные отверстия посылают нахер сам диск! Никаких центров, никаких индикаторов. С одной стороны проточил, зажал в патрон(сторона с проточенной стороны гуляет.. похер). Проточили с другой стороны.(Ну не зажмет токарный патрон диск идеально ровно! Даже очень дорогой! В любом случае контроль с индикатором!). По итогу диск волной! Колодки быстро в хлам! Колесные диски повторяют неровности тормозных! Вибрация по всему авто! При торможении пульсации ногой чувствуются. Экономия епт... п.с. Я думал они предварительно сделают проточку на грубую, а потом установят на финишную обработку в центр ЧПУ! Ну или хотя бы дядя с индикаторами будет точить уже финиш на отдельном токарнике или шлифовальном! Но нет.... По итогу это заготовка, а не готовая работа!(хотя если посадочные проточены до финишного диаметра - то это кусок металлолома, а не диск!)

С босыми ногами на сталелитейном производстве! У меня нет слов 😮

They are literally slaving to produce a product.Real men! Respect!

Imagine breaking engine blocks with hammers barefooted and without glasses. Just beyond belief!

Respect for the man of labour

I'm surprised that after facing and centering the hub, they don't cut both rotor faces at the same time to ensure a concentric final result.

Where I live we have to descend a 3-mile winding slope ,with a 6 to 9 degree angle, sometimes with a laden trailer with bricks or sand. Fitting those discs would be like signing your own death warrant.

As the head safety officer for Pakistan, I approve of the safety sandals and the safety pyjamas worn here. The quick voices you hear, are the result of the furnace gasses. Though our product is shit, we do sell a lot of break disks. The returns normally are from those trucks and buses that have fallen off the mountain cliffs due to brake failure; normally from broken discs made at ours factory, where we use built in obsolescence of 3 weeks, thus ensuring a quick output and a secure customer base.

Each one of these rotors is like a piece of art. It's unique. Different alloy, diameter of holes and dimensions!! Having the holes match those of your car is pure luck!

*While these videos undeniably demonstrate skill and resourcefulness, they area seriously damming indictment of the state of the Pakistan economy*. If a 'workshop' like this was producing one-offs or very small runs of parts that are near-impossible to source, it would be wonderful. For example, if they were making parts (any parts) to order for vintage cars or vintage machinery that simply are not available off-the-shelf, it would be an incredible resource for customers around the world. However, these brake discs are obviously destined for modern vehicles, and I feel certain they're destined for vehicles in the local economy. I seriously doubt that if I go to a parts supplier here in the UK to buy a brake disc, that it was made in this shop. It's an inexpensive part here in the UK, and I have no doubt it was mass-produced (probably in China) with at least better-than-basic quality assurance processes. Assuming Pakistan trade with other countries, which I am sure is true, it is frightening that a motorist in Pakistan would choose to buy a locally made part, made in these circumstances, in order to save what can only be a relatively small amount of money (I reach this conclusion because the imported equivalent would be sold at a price, corrected for local buying power, comparable to the UK price). And before anyone points out that Pakistan is a relatively poor country with low buying power - the buyer of one of these discs owns a reasonably modern car with a reasonably sophisticated braking system. Therefore if you can afford the car, surely you can afford to buy what is an inexpensive component that's been made with proper QA in a proper overseas (i.e. Chinese) factory. So aside from quality concerns, it's reasonable to conclude these workers are being paid a pittance to produce these parts and they're being sold at a price even lower than the low cost of mass-produced imported parts. That demonstrates how poorly the Pakistan economy prices the skill and hard work of these workers If my point still isn't clear - I can buy a mass-market, imported, quality brake disc for around 20 GBP (about 25 US dollars) here in the UK. Imagine I went to a specialist foundry and asked them to make me a brake disc for my car. Once they'd finished laughing at me they'd tell me I can buy it ready-made for about 20 pounds. But I insist I want a scratch-made one. Okay they'd say, we can do that - but it'll cost you 1,000 pounds for such a specialist, small-run job. Whereas, as demonstrated by this video, you can get a local foundry in Pakistan to make you a brake disc for less than the cost of a properly QA'd mass-produced item. I find it absolutely baffling and quite saddening.

While I don't necessarily agree with their quality control methods, I commend these men for their hard work, in very dangerous conditions without any personal protective gear. Bare feet around molten iron. No gloves or safety glasses. Yet I'll bet these men are happy to have a job in this poor part of the world.

i think, metalurgy, friction coefficient, quality and everthing has gone for toss with this skilled labor

Wow the quality control of the mixing of metal alloys is unbelievable 😂

My guess is these are probably discs for trailer brakes, or trailer brake conversion kits. They work, but may not be the highest quality in the world.

Amazing by the amount of work they put inside this, but atrocious by the amount of safety issues those discs might bring with them when installed on your car...

OMG! It truly WAS an amazing process. Love the tongue in cheek description of 'intricate engineering' and 'safety technology'. Had a difficult time understanding the experts explanation of the steps. Whew!

You all can make fun of these guys and their techniques all you want, but as an American, I think it is refreshing simply seeing young men actually CREATING SOMETHING USEFUL instead of selling drugs and robbing liquor stores.

Gotta love the safety sandels!

Они вообще не знают что такое техника безопастности, даже не слышали об этом...😘😘😘

Incridible safety and quality control.

Eso es arte. Los felicito.

тяжёлый труд, и техника безопасности на минимуме, С большим интересом смотрю все Ваши видео

встречайте эти "брембо" и "ТРВ" на всех маркетплейсах!)))))))))))))

I always tell to my boss that flip flops are the best safety shoes but he never believes me.

Wow! All of these brake disks are made by the famous "Roadkill Rotor Company" of India! Superior quality, excellent price and most of all, safety above all. Great stuff, chuckles!

This is the first Pakistani video where a worker used a vernier caliper to measure a thickness which is accurate to 1/10th of a millimeter. Never mind that the particular dimension he measured needs to be accurate in terms of 1/100th of a millimeter. This also surprises me to know that they do have vernier calipers in Pakistan and there are a few individuals who know how to hold them.

i think fred flintstone has the right idea using his feet to brake, far safer.

Very good video. I liked it. Thank you for sharing.

"Watch me free hand lathe the most important part of the safety of your life and the life of your family!" said no one sensible, ever.

i guess those guys have no problem with building F1 car... fair play lads..

This is certainly highly skilled work that is nearly 100 years behind the times, probably the same as their pay which is the sad part about it.

Even Fred Flintstone did not work this hard!

most folks in the west have never worked like this or as hard for over 40 years at least ,ive worked in a furnace and molding room not this small or with so many hand tools ,i had family members back in 1890s to 1950s makeing chains by hand ,and anchors ,parts for railway bridges for all over the world ,ive seen the factory my family worked in bridges in most countries, stamped on them ,horseley fields tipton iron and furance works uk ,all gone these days only one furance and steel plant left ,far play to these guys

They save a fortune in safety glasses!

Harika video olmuş, eline sağlık

очень тяжелый труд, уму непостижимо, всё вручную. Но видео супер просто

How many of you wouldve been pissed if you saw them put those in a Brembo box?...lol

So, this is how Aftermarket brake maker Willwood does it. Good to know.

Great Video, hard workers !

запчасти от лучших производителей!

Safety is our priority

Короче, мне всё их производство напоминает старания коротышек из " Незнайка на Луне". Они же смогли, полетели всё-таки, и не важно, как это получилось.

I just hope the discs made in this video don't end up in any vehicle that I drive or travel in. To me this just highlights the massive distortion of wealth around the globe.

Those guys are making a whopping $58.56 a MONTH (average). I don't know the hourly rate because they probably work 60-70 hours a week but it adds up to $14.64 a week. Much respect for their work ethic.

It's wild that some parts of the world operate like it's 1880. I wouldn't want those rotors on my car !

Ford quality at its finest 👌

Fantastic!

These guys could build an IBM computer with a rock, hammer, and lathe. Their abilities are awesome.

I'm glad to see that they take work safety very serious.

Mis respetos para estás personas son berracos

Os caras são bons no que fazem. Parabéns !!! Pouco recurso e bom resultado. Poderiam dizer quais montadoras utilizam de seus produtos...

Good to see some were wearing safety flip flops.

I love these guys. They sure do make me appreciate my made-in-China stuff more!

At least in this shop they didn't throw machined surfaces on the ground and used actual calipers to measure instead of a bent wire. There's some actual clean floors with parts carefully stacked. A step above a lot of the shops you see presented on youtube.

A lathe makes everything look nice and machined.

Deze mensen doen hun best. De omstandigheden zijn mens onterend. Geen enkele veiligheid maatregels is hier van toepassing. De bazen zijn te beroerd om het fatsoenlijk te bestraten.

as a human being i just want to weep for these men, the conditions they are working in is so UN-healthy.

В целом производство как производство.Ну нет линии формовки,ну при существующей зп это у них оправдано скорее всего.Станки простецкие но целые и чистые.В целом для литейки очень даже порядок.Пыли особо не видно,так как выбивка в ручную и ласково.Если честно на том же ЧТЗ все намного страшнее,народ как ежики в тумане их там в пыли и не видать,силикоза много (бывал я на многих предприятиях литейных,закупаем отливку постоянно).

Working conditions and worker safety, unimaginable. The same goes for product quality. At least where I come from.

Maravilhoso trabalho, mas usem óculos de proteção para evitar perderem a visão por acidente de trabalho guerreiros!

Once finished , it' send to Italy and rebadge as BREMBO with premium price

What in the OSHA is going on here?! Just kidding. I love these videos. These are some very hard working people. Respect.

Thea’s guy’s make it look so easy a credit to them 😊

Which ever way to look at quality or the end product, this Is extremely hard work!! These guys deserve a lot of kudos for being able to make brake pads from scrap metal.

I would trust them brake discs as much as I trust the glue on the Titan submarine... 🙄🤨

Recycling at its finest! I love it.

I never knew Mintex disc were made this way! 🤣🤣🤣 You would have to be a brave man to fit those.

Nice "crusher" and "conveyor belt" system! Fully automated. 😮

What a sophisticated technology? The Germans can only dream of something like that ;)

Somebody please give those guys some safety shoes and some eye protection!!!

Ingenious field engineering!

This is India?

The epitome of "work harder, not smarter".

I can’t have a gas stove, but this is happening. I love their effort as they have to do what they have to do. I love the entrepreneurial spirit. Will any of there guys see 52 with what they are inhaling?

The protective safety sandals are top-notch. ;) The brake rotors produced are of questionable quality. They weigh the amount of cast iron and scrap iron but that's not more than a rough benchmark. No metallurgical testing, no quality control, stress test, test for hardness, or whatever. I guess they can sell these things to Lada... 😂 The people at Toyota get shivers when they see "Hiace" on the drilling guide. However, they get things done with what they have..

Love the feet and eye protection! 😮

Amazing work, really is 👍

Техника безопасности у них на высоте . В горячем цеху в шлепках и халатах... А вообще молодцы , труд очень тяжелый , многое в ручную , особенно как разбивают двигателя...

Вот оказывается что означает выражение расколоть движок ! 🤣🤣🤣

Looks like a well clean cast iron no pockets and concentricity aligns well, how the friction material will do against the disk is a question but as for the machining is very good

Can hear Jawa's managing things around.

Impressive, quality control, precision... I wouldn't mount em on 20hp car.