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Car Forum / Driving, Maintenance, Tuning / Maintenance and Repair / November 2006

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Disc Brake rotor runout

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Lawrence Glickman - 04 Nov 2006 13:57 GMT
Yah have to be kidding.

Yesterday I popped for a runout gauge, and was all confident that when
the need arises, I can measure rotor warp and runout without any
problem.

Until,
I got to the "Specifications" part of my Workshop Manual,
in which it says:

Brake disc maximum runout 0.05mm (0.002 in )

Now, I took my digital verniers ( a different tool ) and set it up to
0.05mm.  Holding it up to my eye, I could barely detect LIGHT coming
through the jaws, so then I pulled a HAIR OUT OF MY HEAD and measured
that thickness.  

Hair = 0.07mm in thickness.

So...If I got this right, and I can't see how I didn't, the maximum
allowable rotor runout is a FRACTION OF THE THICKNESS OF A HUMAN HAIR.

This can't be right.

I bet my last nickel, which I have here on my desk, that if I measure
the rotor runout on even a NEW CAR, the runout is going to exceed the
thickness of a human hair.

WHAT'S UP WITH THESE SERVICE MANUALS?  Who writes them?  Are they
under the influence of hallucinogenic drugs?

Lg
HLS@nospam.nix - 04 Nov 2006 14:28 GMT
> Yah have to be kidding.
>
[quoted text clipped - 28 lines]
>
> Lg

Try it and see, Glickster.  My manual says 0.004 inches for my particular
application.
If you dont want them to wobble and shimmy, then they need to run true.

How true?

True enough to satisfy you.
Lawrence Glickman - 04 Nov 2006 14:31 GMT
>> Yah have to be kidding.
>>
[quoted text clipped - 28 lines]
>>
>> Lg

=====================================================================
>Try it and see, Glickster.  My manual says 0.004 inches for my particular
>application.
[quoted text clipped - 3 lines]
>
>True enough to satisfy you.

I can see the HUB having that tolerance, but the rotor ??!!!????

I'll measure them _both_ and get back to the group.  This defies
logic.

Lg
TeGGeR® - 04 Nov 2006 16:42 GMT
>>> WHAT'S UP WITH THESE SERVICE MANUALS?  Who writes them?  Are they
>>> under the influence of hallucinogenic drugs?
[quoted text clipped - 15 lines]
> I'll measure them _both_ and get back to the group.  This defies
> logic.

Just checked my Integra's factory shop manual. Same thing.
Front runout: .004"
Rear runout: .006"

But look at the parallelism number: .0006"
Six TEN thousandths of an inch!

No runout figures are given for the hubs themselves.

Signature

TeGGeR®

Daniel - 04 Nov 2006 17:01 GMT
> Yah have to be kidding.
>
> Yesterday I popped for a runout gauge
================
Just because it's digital doesn't necessarily mean it is accurate.
I use a threaded micrometer, and dial indicator with mechanical sweep
hand that I've had for years.
IIRC the disk runout maximum on my import FWD is 0.0020, and the sealed
bearing for the front wheel is 0.0010.
Recently checked and both were within spec.
With the mechanical gauges you can move something very slightly and see
the movement on the pointer. .002" is correct.
I use a brass dial type tire pressure gauge with bleed off valve and
find it much more accurate that a digital pressure gauge I was given as
a gift.
Especially if you've got an inexpensive runout gauge, I'd be skeptical
of the precision.
Lawrence Glickman - 04 Nov 2006 21:44 GMT
>> Yah have to be kidding.
>>
>> Yesterday I popped for a runout gauge
>================
>Just because it's digital doesn't necessarily mean it is accurate.

This is true of any measuring device.  Accuracy and precision are two
different things.

precision is to X decimal places, the more the merrier, but that does
not mean those numbers are accurate.

>I use a threaded micrometer, and dial indicator with mechanical sweep
>hand that I've had for years.

I have a Brown and Sharp threaded micrometer I inherited from my
father, who was a Mechanical Engineer, educated at M.I.T.  It is
plenty accurate, although it has a vernier scale, which is a PITA for
an old man like myself with fading eyesight.

>IIRC the disk runout maximum on my import FWD is 0.0020, and the sealed
>bearing for the front wheel is 0.0010.

I expect the hub and bearing to be TIGHT.  Tolerance wise.  On my car,
they are available to the public as an assembly, with the bearing
already pressed into place.  I checked with Rock Auto, and I can get
the ass'y for $56 online.  I'm not sure if shipping and handling are
extra.

>Recently checked and both were within spec.

I use a set of Mitutoyo vernier calipers as my *standard.*  If it is
good enough for Panasonic Factory Automation, it's good enough for me.

>With the mechanical gauges you can move something very slightly and see
>the movement on the pointer. .002" is correct.

Just because something is inexpensive doesn't mean it isn't accurate.
We've been trained to *think* you _have_ to pay more for accuracy.
Sometimes yes, sometimes No.

>I use a brass dial type tire pressure gauge with bleed off valve and
>find it much more accurate that a digital pressure gauge I was given as
>a gift.

I use an analog tire pressure gauge also.  The digitals are
notoriously inaccurate, but that might be because of the pressure
transducer rather than the rest of the setup.

>Especially if you've got an inexpensive runout gauge, I'd be skeptical
>of the precision.

I measured it against the Mitutoyo Verniers.  It's pretty much *tits
on* for the 25mm of travel.

Accuracy is +/- 1000 inch.  Since I'm looking for VARIATION here
rather than Absolute Value, it will suit this job.

Lg
Ashton Crusher - 06 Nov 2006 05:56 GMT
>>I use a brass dial type tire pressure gauge with bleed off valve and
>>find it much more accurate that a digital pressure gauge I was given as
[quoted text clipped - 3 lines]
>notoriously inaccurate, but that might be because of the pressure
>transducer rather than the rest of the setup.

How do you know the analog gauge is giving you the right reading and
the digital the wrong one.  I've rarely seen two different analog
pressure gauges give the same reading but several different digital
ones I've got all give the same pressure.  Doesn't mean it's right but
it's the same which is more then the analogs.
Lawrence Glickman - 06 Nov 2006 07:24 GMT
>>>I use a brass dial type tire pressure gauge with bleed off valve and
>>>find it much more accurate that a digital pressure gauge I was given as
[quoted text clipped - 9 lines]
>ones I've got all give the same pressure.  Doesn't mean it's right but
>it's the same which is more then the analogs.

That is information, correct or incorrect, that was passed along on a
Ray and Bob show.  These guys do Car Talk.  They have a website.  They
are graduates of MIT, and I a.s/u/me that because of their higher
level of education, they know what they are talking about.  Many other
people make this same assumption.  They also run a car shop, and speak
from their own experiences.  In fact their *job* is to give car
experience to other people.

Since they broadcast on radio, and have an open website, challenges to
their ideas would appear from everywhere.  I've never seen anyone
challenge them on the analog vs. digital pressure gauge issue.

Lg
Ashton Crusher - 08 Nov 2006 06:11 GMT
>>>>I use a brass dial type tire pressure gauge with bleed off valve and
>>>>find it much more accurate that a digital pressure gauge I was given as
[quoted text clipped - 23 lines]
>
>Lg

I love their show, it's very funny, but I have heard them give bad
info occasionally.  They may have had a bad experience with the first
digital gauges years ago and just keep passing it on.
Lawrence Glickman - 06 Nov 2006 08:14 GMT
>>>I use a brass dial type tire pressure gauge with bleed off valve and
>>>find it much more accurate that a digital pressure gauge I was given as
[quoted text clipped - 9 lines]
>ones I've got all give the same pressure.  Doesn't mean it's right but
>it's the same which is more then the analogs.

That is information, correct or incorrect, that was passed along on a
Ray and Bob show.  These guys do Car Talk.  They have a website.  They
are graduates of MIT, and I a.s/u/me that because of their higher
level of education, they know what they are talking about.  Many other
people make this same assumption.  They also run a car shop, and speak
from their own experiences.  In fact their *job* is to give car
experience to other people.

Since they broadcast on radio, and have an open website, challenges to
their ideas would appear from everywhere.  I've never seen anyone
challenge them on the analog vs. digital pressure gauge issue.

here they say *some* digital gauges are "surprisingly accurate"
==================================================================
Dear Tom and Ray:

I have three different tire gauges, all of which give me different
readings. They are all the old-style "pencil type" gauges, and all are
made in China, if that makes a difference. How do I find one that can
be trusted? -- Jerry

RAY: Well, the pencil-type tire gauges, with the pop-up plastic
readouts, are notoriously inaccurate. You could buy five more of them,
and you'd probably get eight different readings.

TOM: And the dial-up gauges used on air pumps at gas stations are even
worse. You set it for 32 psi, you hear "ding-ding, ding-ding,
ding-ding," and you drive away with 80 pounds of air in your tires,
with your head bouncing off the ceiling.

RAY: We use a very precise dial gauge at the garage that cost us about
100 bucks, and it's a beautiful instrument. We keep it under lock and
key, because if we didn't, my brother would use it as a hammer to free
up stuck brake calipers, or to crack chestnuts.

TOM: But I'll tell you what. We got some samples of some inexpensive,
battery-powered plastic gauges with digital readouts. Surprisingly,
they were extremely accurate. You can get them at almost any
auto-parts store now. They cost 15 or 20 bucks, and they use
replaceable batteries.

RAY: Yeah. The batteries cost 14 bucks.

TOM: Nah, they're watch batteries; 3 or 4 bucks a pop. In any case,
whoever makes these gauges (and I'm sure at least some of them are
made in China), this style seems to be far more accurate than
pencil-style gauges. So, that's what we'd recommend for you, Jerry.

http://www.cartalk.com/content/columns/Archive/2005/June/07.html

===================================================================

You'll note the STANDARD they keep "locked up" as a reference is a
dial type.

Humans being contrary critters, here is what Tom and Ray have to say
about dial gauges:
===================================================================

Dear Tom and Ray:

My question is in regard to proper tire pressure. When you buy a new
car, the owner's manual tells you to abide by the sticker inside the
door post. My present car calls for 30 psi in all four tires. But when
I get the car back from the dealer, the tires generally have 36-38
psi. Do they know something I don't? -- Howard

Ray: No, you apparently know something they don't, Howard. Either
their equipment is inaccurate, or they're just being careless.

Tom: Or perhaps, after the Firestone tread-separation debacle, they're
so afraid of underinflating tires that they're being overzealous and
overinflating them.

Ray: But you're absolutely right, Howard. If you have the original
tires on your car, or approved replacements that are the same size,
then the pressure recommendation in the owner's manual (or on the door
post) is the one to follow.

Tom: Just be sure YOUR measurements are accurate. You have to use a
good-quality tire gauge.

We recommend the round gauges with the needle, rather than the
^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^
"pencil" type gauges with the pop-up indicator.
^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^
Ray: And be sure you're measuring the pressure when the tires are
relatively cool, since heat from driving can dramatically increase the
pressure. So if you take a 30-minute drive home from the dealer --
including a jaunt on the highway -- and then hop out of the car and
measure the pressure, it's likely to be inflated by the heat generated
during the drive, and it will give you an inaccurate reading.

Tom: But if you're checking the pressure with a good gauge when the
tires are cool, you have every right to ask the guys at the dealership
(nicely) to shape up and be a little more careful from now on.

http://www.cartalk.com/content/columns/Archive/2001/April/05.html

======================================================================

So here, they contradict themselves and "recommend the round gauges
with the needle."

So which is it?
On their advice, I threw away what I thought was a perfectly GOOD
digital pressure gauge, and went out and bought an analog dial gauge.
Now they turn around and say digital.

Lg
Ashton Crusher - 08 Nov 2006 06:14 GMT
>>>>I use a brass dial type tire pressure gauge with bleed off valve and
>>>>find it much more accurate that a digital pressure gauge I was given as
[quoted text clipped - 50 lines]
>auto-parts store now. They cost 15 or 20 bucks, and they use
>replaceable batteries.

BUt you'll notice that they just assume the $100 analog gauge is
correct.  They also seem to be saying that the cheap digitals give
pretty much the same answer.  Most people will not pay $100 for a
super quality analog gauge, they will either pay $5 for a cheap, and
inaccurate, analog gauge, or $10 for a fairly accurate digital gauge -
the opposite of what the start of this thread implied they should do.

>RAY: Yeah. The batteries cost 14 bucks.
>
[quoted text clipped - 65 lines]
>
>Lg
Ashton Crusher - 08 Nov 2006 06:19 GMT
>>^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^
>Ray: And be sure you're measuring the pressure when the tires are
[quoted text clipped - 21 lines]
>
>Lg

Yup.  I think they made the whole thing confusing by bringing the
pencil type gauges into the discussion.  Those things are horribly
inaccurate. Then they seemed to suggest you should use a gauge with a
"needle" but really confuse that issue by talking about their $100
gauge when everyone is only going to spend $5 on one.  You would be
lucky to find two regular analog gauges that agreed within 2 psi of
each other.  My digitals are all within 0.5 psi of each other.
Lawrence Glickman - 08 Nov 2006 10:16 GMT
>>>^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^
>>Ray: And be sure you're measuring the pressure when the tires are
[quoted text clipped - 21 lines]
>>
>>Lg

==============================================================
>Yup.  I think they made the whole thing confusing by bringing the
>pencil type gauges into the discussion.  Those things are horribly
[quoted text clipped - 3 lines]
>lucky to find two regular analog gauges that agreed within 2 psi of
>each other.  My digitals are all within 0.5 psi of each other.

I think I am through buying tire pressure gauges for a while.  No
matter which kind I get, analog dial or digital, I'm never going to
know if it is ACCURATE anyhow.  I have no STANDARD against which to
measure them.

So I have an analog, and am using that, and when it breaks, ( I should
live so long ) I might consider going back to the digital I had to
begin with, which never gave me any problems anyhow.  I was happy with
that digital pressure gauge until I listened to their show.  Bummer.
If these guys suddenly like digital so much, maybe -they- can pay for
a new one for me.  fat chance.

Lg
Stephen H - 13 Nov 2006 04:42 GMT
> I think I am through buying tire pressure gauges for a while.  No
> matter which kind I get, analog dial or digital, I'm never going to
[quoted text clipped - 9 lines]
>
> Lg

Just went thru the same thing- bought on pressure chuck from snap-on and an
tire pressure gauge and pressure chuck form S&K. All seem to read
differently. If you can find one and want to pay for it a "master" tire
gauge is what your sup;pose to check them against.

Signature

Stephen W. Hansen
ASE Certified Master Automobile Technician
ASE Automobile Advanced Engine Performance
ASE Undercar Specialist

http://autorepair.about.com/cs/troubleshooting/l/bl_obd_main.htm
http://www.troublecodes.net/technical/
http://www.familycar.com/Alignment.htm

Lawrence Glickman - 13 Nov 2006 15:44 GMT
>> I think I am through buying tire pressure gauges for a while.  No
>> matter which kind I get, analog dial or digital, I'm never going to
[quoted text clipped - 14 lines]
>differently. If you can find one and want to pay for it a "master" tire
>gauge is what your sup;pose to check them against.

This seems to be a problem, digital vs. analog.  People think that
because their computers give them Accurate numbers that it follows
that anything Digital is accurate.  Well, that just isn't the case.
The digital tire gauge can be off 7 pounds psi consistently, and who
would know?

That is why I go by Tire Wear Patterns, and Steering and Handling.

I can feel if a front tire is over/under inflated by looking at the
wear patterns of the tread, and feeling how much effort it takes to
turn the steering wheel.  IOW, IMO, the Ultimate Tire Pressure Gauge
is your own tire treads.

Short of that, you pays your money and you takes your chances.  This
is one of the more important things about car maintenance, but because
it is so simple to do, people ignore it.  This is the material ( tire
tread ) that stops you when you hit the brakes.  Not enough tread in
contact with the road (overinflation), and you've compromised your
braking system, not matter how good everything else is about the car.
Underinflate, and you wear off the sides very quickly, and the center
of the tread isn't putting enough pressure on the road to do you much
good.

So because of my own tire wear patterns, I'm running what my analog
gauge says is 32 psi in my tires, instead of the 30 psi printed on the
door sticker.

Maybe the gauge IS accurate, but for these tires, my vehicle, I need
32 psi to get a proper tire tread wear pattern, and handling that
*feels right.*

I've noticed that if I run at 30 psi, the ride is mushy, and the outer
edges of the tread wear off leaving the middle of the tread pretty
much untouched.  So those Two Measly Pounds of pressure make a
difference, at least on my vehicle.

Regarding the gauge, I'll continue to use what I have, because no
matter what the gauge says, that's only part of the problem.  You have
to look at treadwear patterns, steering and handling, ride comfort,
and good footprint for braking.  It all comes together, but the gauge
-alone- isn't the whole answer to the question.  IMO.

Lg
Don - 04 Nov 2006 17:37 GMT
>Yah have to be kidding.
>
[quoted text clipped - 19 lines]
>
>This can't be right.

I don't know about the human hair, but .002" IS right.  I use a dial
indicator and typically find readings of .0015 or so on good rotors.
Depending on the vehicle a pulsation may be felt if it gets up around
.004 -.005.

Don
www.donsautomotive.com

>I bet my last nickel, which I have here on my desk, that if I measure
>the rotor runout on even a NEW CAR, the runout is going to exceed the
[quoted text clipped - 4 lines]
>
>Lg
shiden_kai - 04 Nov 2006 18:32 GMT
> I got to the "Specifications" part of my Workshop Manual,
> in which it says:
>
> Brake disc maximum runout 0.05mm (0.002 in )

That's correct.  You normally will not feel "runout" through
your brake pedal, but "runout" eventually leads to
"thickness variation"....and that's what you feel when
the brakes pulsate.  Which is why the runout measurement
is so important.  It will eventually cause a brake pulsation,
but if often does not show up for 10-12K kilometers.

Ian
HLS@nospam.nix - 04 Nov 2006 19:13 GMT
> That's correct.  You normally will not feel "runout" through
> your brake pedal, but "runout" eventually leads to
[quoted text clipped - 4 lines]
>
> Ian

That is the wisdom of the day, and there is truth to it, but at
the end of the day, when you start feeling the wobble/shimmy,
eventually something has to be done.  Realizing there there
is more to the issue than just disc warpage is helpful.

You CAN feel runout as buffeting/jitter at some level, because there
is mass to the caliper. If you have to use energy to move that mass from
side to side, there will come a point it can definitely be felt, but perhaps
not in the brake pedal. (and perhaps so).

If the caliper were without mass, and if there were no viscosity effects
to the brake fluid on dual and quad pistoned calipers, then you might
feel nothing.

Thickness variation is another side to the coin.  You will definitely
feel it in the brake pedal.  It adds to the jitter in a minor way.

So, what do you do?  Normally if you machine the rotors, the problem
goes away.  It may not stay away.

If the hub has too much runout you may have to change it, or at least
shim or index the disc so that the whole thing comes into spec. You have
to clean the surfaces so that when you bolt it all back together, there is
no rust or dirt or corruption to keep you from truing up.

Of course, the disc must be true, properly surfaced, and of adequate
thickness.
Some discs can be machined, others may have to be replaced.

Having good measuring tools helps you find out exactly what is going
wrong, and for those who want to effect a long term cure, not just a
cheap 'fix', it should be possible if you understand the nature of the
system.
shiden_kai - 04 Nov 2006 21:19 GMT
> You CAN feel runout as buffeting/jitter at some level, because there
> is mass to the caliper. If you have to use energy to move that mass
> from side to side, there will come a point it can definitely be felt,
> but perhaps not in the brake pedal. (and perhaps so).

I'm going to disagree with you.  What usually happens is that
you "hear" runout if it's extreme.  You will hear the caliper banging
back and forth, but if the disc is completely parallel...you aren't
going to feel any pulsation in the brake pedal.

I've experience extreme runout just by having a brake lathe that
wasn't centering the rotor properly while it was being machined.

Ian

> If the caliper were without mass, and if there were no viscosity
> effects
[quoted text clipped - 21 lines]
> cheap 'fix', it should be possible if you understand the nature of the
> system.
hls - 04 Nov 2006 21:48 GMT
I know what you are saying, but you dont get away from some
irritating jitter or shimmy, whether it pulsates through the pedal
or not.

Maybe you hear it, maybe you sense the jitter or shimmy, and
as I agreed, perhaps you dont feel it in the brake pedal (as pulsation).

There will be mechanical vibration due to the inertial mass of the caliper
being slapped around by a  disc which now has the profile of a camshaft.

The beginnings of irritation.....

The pedal pulsation effect, as earlier agreed, is caused by thickness
variations
in the disc.

To fix the problem, sometimes you have to do more than just turn the rotors.

Are we still in disagreement>?

>> You CAN feel runout as buffeting/jitter at some level, because there
>> is mass to the caliper. If you have to use energy to move that mass
[quoted text clipped - 36 lines]
>> cheap 'fix', it should be possible if you understand the nature of the
>> system.
shiden_kai - 05 Nov 2006 00:06 GMT
> To fix the problem, sometimes you have to do more than just turn the
> rotors.

Very true....but the problems that come about because of
even very minor runout usually don't appear until a number
of miles down the road.  Which is why we often used to
blame the driver, the rotors being thinner because of
machining them....etc.

Ian
Andy Dingley <dingbat@codesmiths.com> - 08 Nov 2006 21:02 GMT
> So...If I got this right, and I can't see how I didn't, the maximum
> allowable rotor runout is a FRACTION OF THE THICKNESS OF A HUMAN HAIR.

Surprise yourself. Even gauging them with just a thumbnail you can
_feel_ runout at this level when you  haven't a hope of seeing it.

... And it matters too.
Lawrence Glickman - 08 Nov 2006 21:45 GMT
>> So...If I got this right, and I can't see how I didn't, the maximum
>> allowable rotor runout is a FRACTION OF THE THICKNESS OF A HUMAN HAIR.
[quoted text clipped - 3 lines]
>
> ... And it matters too.

Of course it matters.  Everything matters.  

I don't have the time to do this now.  Car is in constant use for
medical issues relating to the family.  But sometimes when I'm out
waking around, I take a look at the disc brake rotors on other
people's cars.  My experience shows most have rotors on the front, and
shoes on the back.  This is my setup also.  Rotors on front, shoes on
back. This cursory inspection problem I have might go along with my
diagnosed Obsessive Compulsive Behavior diagnosis.  It is becoming a
very very weird habit.

Somebody might ask me why I'm looking at people's rotors.  I don't
have a good answer for that, but some of them look, quite frankly,
like sh.t.

When I get to mine, I'll be measuring hub runout, rotor runout, runner
thickness and variation, and measuring the caliper PADS to make sure
they have enough stop-stuff left on them for the winter.

I believe this all began LAST WINTER when I read an article in the
paper about a Van with kids and mother that ran into a creek, where
they all drowned to death.  The cops said the brakes were shot and
that is why the vehicle went out of control...wouldn't stop.  They
were on a paper delivery route...IOW a huge amount of Stop & Go, which
is sure to burn up brakes quickly.  Now they are all dead.  So yes, it
matters.

Lg
hls - 08 Nov 2006 23:44 GMT
So yes, it
> matters.
>
> Lg

Of course it matters.  Tire and brake condition are two factors which stand
between you and the coffin.
Lawrence Glickman - 09 Nov 2006 00:07 GMT
> So yes, it
>> matters.
[quoted text clipped - 3 lines]
>Of course it matters.  Tire and brake condition are two factors which stand
>between you and the coffin.

Fortunately, servicing brakes isn't rocket science.  Even I can do it.
The problem for a lot of people is, out of sight, out of mind.  You
wouldn't believe how bad a lot of rotors look out there in carland.
Of course the newer models aren't old enough to show neglected brake
service, but older cars, most of them, look like death on wheels.

I have all the tools now to do the job right.  I last checked them
this past summer and they looked OK.  But now I have the measuring
stuff to go in there and really log some numbers.

I would rather _not_ leave this to some shop.  The last time I took my
car to Auto Clinic, they reamed my wallet, and reamed my vehicle.
They did a butcher job on the rotors.  I should have filed a complaint
with the Better Business Bureau.  But now that I know how to do this
myself, it will be done correctly from now on.

I still have to flush my lines, and do have the equipment for that
also.  When I finish learning how to STOP A VEHICLE RELIABLY, then I
will spend more time on learning how to make it GO reliably.  This is
a combination of study, and experience, and having the right tools.

Lg
 
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