Z1 Front Rotor Lockwashers - Distorting

OK. So I've just rebuilt my front hub, - new bearings/seals etc. Laced into a new rim, mounted a new tire etc.

Everything's going great until I go to fit one of the two new rotors. 6 brand new bolts, 3 brand new two-bolt locking 'tab' washers. Threads were chased. I'm using Loctite blue on the bolts.

FSM gives a torque range of 25-33 ft/lbs. I set my click-style torque wrench at 15 lbs for a first pass. All is fine. I bump it up to 22 for a second pass, and notice that the lockwashers are distorting under the bolt heads - buckling and twisting. By the time I get to 30 for my final clamp down, the lockwashers are almost torn in two.

There are no regular washers under these bolt heads obviously as this would make the tabs on the lockwashers useless, so it's obviously the underside of the bolt heads that are biting into the lockwasher and causing this distortion. (The Factory Parts Manual shows nothing but the bolts and the lockwashers either.)

Has anyone else had this problem, or am I just doing something really dumb here?

I haven't heard about this happening, but there is no real need to use lock washers if you are using lock tight; unless you are going for a resto of course. Are you using the stock flange bolts? perhaps put the tiniest film of grease under the flange to prevent the bolt from biting in the soft lock washer.

Here's a pic of the problem:




Any ideas?

DoctoRot wrote: I haven't heard about this happening, but there is no real need to use lock washers if you are using lock tight; unless you are going for a resto of course. Are you using the stock flange bolts? perhaps put the tiniest film of grease under the flange to prevent the bolt from biting in the soft lock washer.

Yep the bolts are stock - brand spanking new from Z1 Parts as part of their dual disc conversion kit.

I might just scrap the lockwashers, clean up the bolts, add flat and spring washers and hit them with some red Loctite.

It's along the lines of a restoration, but I'm not looking to build a trailer queen by any means. There are a number of parts that were chromed by one of the POs that I'm not going to change back to standard, so I'm not looking for any more than 95% originality.

Looks like the locking tabs are too soft of a material

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