Shortly after Interbike 2013, Wayne Moore left Ashima after quite a few years of developing lightweight brake rotors and parts. Between then and now, he’s been busy revamping the design and launching new rotors under his own company, Legion.
Two models will be offered – a one-piece and two piece. The Javelin D-Drive two piece rotors use an alloy carrier with a 420 stainless steel that are machined to nest into each other. That locksteps their rotation so the pin joining them doesn’t need to handle a load. So, he’s able to use an alloy pin rather than steel, which helps pull heat away from the rotor faster. It’s a no-rivet operation, and the pin floats freely, held in place with a star lock washer that takes about 150kg of force to pull apart.
Moore says the design is also stiffer since the pieces are tucked into each other.
Dovetailing the parts together means the rivet doesn’t need to use as much force to keep them connected, allowing for a true floating design. Moore says that means less distortion, so the rotor is more true.
The Discus one piece rotor squares up the aesthetic of Ashima’s Ai2 rotors to eliminate any pulsing. He also switched from using 410 to 420 stainless steel, making it harder and stronger. The dual leg design means it should be stiffer, too.
His new brake and shift cable housing is 40% lighter than standard thanks to swapping out most of the steel cables for aluminum. Five are steel (darker ones) to keep it strong enough under compression, and 12 are alloy to save weight. The brake housing gets the Kevlar wrap shown here to ensure firm braking.