I just picked up a pair of XX rotors on Ebay at a reasonable price, with the idea of having them custom cut. I contacted CTS Moto this afternoon and mentioned that I'd like to have some rotors cut to replace my current front rotors. Their reply was that they only cut rear rotors because cutting front rotors was "unsafe".

I was surprised. Are you?

That's strange, Mike told me he could cut the fronts but only in a scalloped style. Might e-mail Mike directly he can send an image. I'd send mine but I already deleted it.

One thing is for sure, you would need a competent machinist and well thought out design.

If the outside profile was not concentric with the center there would be a serious balance issue. Also, since the rotor has existing holes balancing after the cuts would be a necessity.

Also, the cuts would need to be smooth--no cutter 'chatter' marks or sharp inside corners--that is where cracks are most prone to start.

If planed and executed well, there is no reason they should not be a safe & reliable as rotors that started life with the profile you are seeking---if available. I say this as a long time machinist but admittedly I am not a metallurgist.

Thought about doing mine---but there is a lot of work involved in doing it 'right' and I'm not as ambitious as I was a young pup---happy trails kel

I would also question the cost to do this vs. buying new wave rotors. It may be cheaper to cut factory rotors, but is it worth it? My concerns would be weakening from the heat, balancing and cracks related to tool marks as Kel noted. Keep in mind Bob you tend to travel a little. A failed rotor can really f-up the trip

Damn, we will have to stock replacement cut front rotors along his route now.