Services

When a customer's brake or clutch arrives at our brake relining facility, we make sure the quantities match up with the paperwork and visually inspect the brake or clutch parts for any obvious faults. We measure the lining length, width and thickness and raise a 3 part workshop reline form, adding the customer's details, quantities and size's of brake or clutch parts and the brake relining process we will use. The bottom part of the reline form is attached to the customer's paperwork and put in the office for pricing, the top two parts of the workshop reline form stays with the brake, clutch parts throughout our relining process. When the job is complete the middle copy of the workshop reline form is matched to the bottom copy in the office and the goods are invoiced. The top copy is left with the brake, clutch parts until they are despatched or collected.

Thermal Bonding

First job is to strip off the old brake or clutch lining. This can be achieved in a few ways: we can use our de-bonding furnace which applies a flame onto the old brake shoe & brake lining, this excessive heat breaks the bond. This process is not suitable for Aluminium brake shoes. If not suitable for de-bonding, we will grind the old brake linings off using our flat bed linisher, or if a clutch disc we can machine off on the lathe. All processes are linked to dust extraction units. When the old brake, clutch lining is off, we will shot blast the metal parts if suitable. We then check again for any obvious faults in the metalwork. The platform of the brake shoe, of face of the clutch disc will then be keyed and our thermal adhesive will be applied. We then cut the appropriate size of brake lining, clutch facing, and key the mating side and apply our thermal bonding adhesive. We then leave both parts for the thermal adhesive to cure overnight. The next step is to attach the brake lining, clutch lining to the brake shoe, clutch disc. If suitable we use our pneumatic or hand brake shoe expander, where a steel band is placed on the outside of two shoes, the expander is activated and pushes the shoes with the lining in place outwards onto the steel band, applying a constant force around the entire brake lining. We then fit a holding device to hold the brake shoes in place, and de-activate the brake shoe expander and lift them out. We then apply a few clamps to try to avoid slipping in the oven. If the brake shoe, clutch disc is not suitable for use in the expander, we will then choose the appropriate metal former and clamp the brake lining, clutch lining to the brake shoe, clutch disc, again applying a constant force around the entire brake, clutch lining. When we have a suitable quantity of work for the bonding oven, we place the clamped brake shoes, clutch discs in the oven and bake for 1 - 2 hours. When the bonded brake shoes, bonded clutch discs have cooled down, we take off all clamps and formers, dress the sides of the parts taking off any excess brake or clutch material. Then we paint the relined brake shoes or relined clutch discs using our traditional Hammerite blue paint. Quite often our vintage brake shoe & classic brake shoe customers ask for their aluminium relined brake shoes not to be painted.

Riviting System

First step is to take off the old brake lining, clutch lining. This can be achieved if metal parts suitable using our pneumatic de-riveting machine. If not suitable for this process, we can punch the old rivets out using hand tools. Again this work is carried out in a controlled environment using our dust extraction facilities. With the old brake linings, clutch linings taken off, if suitable the metal parts are shot blasted and we lightly skim the brake, clutch platform area to take off any obvious high spots. Where pre-formed commercial brake linings are used we paint the brake shoe, and reline using our pneumatic riveting machine. To reline marine winch bands, we will cut the appropriate thickness of non asbestos woven brake lining to the correct length and width. Clamp the brake lining onto the brake band, drill through the brake lining using the correct size of drill. Once the brake band lining is drilled to match the brake band, we paint the brake band with our hammerite blue paint. We then countersink the woven brake lining to the correct depth, using the correct size of countersink tool. We then match the drill woven brake lining material up to the metal brake band, and put the correct size of copper countersunk rivets through the holes. We then start turning over the rivets, using our specially designed winch band riveting tools. To reline clutch plates by riveting, we cut the appropriate thickness and size of clutch facing, clamp onto the clutch plate and drill out using the correct size of drill. Once the Clutch lining is drilled out we paint the clutch plate with our hammerite blue paint. We then countersink the clutch discs to the correct depth using the correct countersink tool. We match the clutch linings up to the clutch disc and put the correct size of copper rivets through the holes. We then start turning over the rivets using either our pneumatic riveting machine or if less pressure required, our bench riveting tool. On some occasions, Mobile Crane Kessler Brake Shoes being one, customers may ask for their brake shoes or clutches to be riveted and bonded. This is achieved by a combination of both processes. .

Cold Bond System

We reline Warner Electric and other makes of electro magnetic clutch and brake units using our cold bond adhesive. We can't thermal bond these electromagnetic brake units as the electric coil is integrated into a resin and the heat used during thermal bonding would possibly damage the electric coil. We skim out the old brake, clutch lining, key the remaining metal and resin face and apply our cold bond adhesive. We cut a friction disc to suit the size and thickness required. We then key the mating surface of the friction disc and apply our cold bond adhesive. The friction disc fits into the electro magnetic clutch, brake recess and we apply a constant pressure using a flat metal disc former and clamps. The cold bond adhesive cures overnight and we take off the clamps. WE then skim the friction facing to the required thickness and skim the mating armature plate flush.

Contact Us

For further information on the services we offer or for testimonials please email us.

Jim Jack Services & Distribution
16-18 Tannoch Place
Lenziemill Ind Estate
Cumbernauld G67 2XU

Tel: 01236 725600
Fax: 01236 725597
Email: info@jimjackservices.co.uk