tsbigdog said:
Sorry to interject into your discussion, but could one of you explain to me what benefit is gained by maintaining the surface area on a drilled rotor? Is it for heat dissipation? I was always told drilling rotors was to help scavenge the gasses that build up between the pads and the rotor under braking.
There are two important "surface area" considerations.
First, there is the total surface area of the rotor. The greater the ratio of the surface area to the total volume of the rotor, the faster the rotor will cool, generally speaking. As oxford stated earlier, drilling does not greatly affect this total surface area. It will reduce it by a small amount, however, if the holes are properly camferred.
Second, there is the surface area of the rotor that actually contacts the pads. This area is of great importance (bigger is better!) and drilling will always reduce the size of the contact area. Any large contact area between the pads and rotors is important for being able to turn friction into heat (e.g. stopping you effectively) and also for pulling heat away from the smaller pads and into the rotor itself, thereby reducing outgassing from the pads and, in extreme circumstances, boiling of the brake fluid.
The trick with drilling is to find that happy medium where the outgassing from the pads doesn't get stuck between the pads and rotors (known as brake fade) while keeping enough surface area to allow decent grip and heat transfer.
Too much drilling and you get poor stopping power and/or overheated rotors (which can then lead to warped rotors, boiled brake fluid, excessive brake pad wear, etc). Not enough drilling and you get brake fade as things heat up.
One semi-related note: The hotter something is, relative to the other objects in which it is in contact, the faster the two object transfer heat. For instance, a rotor at 800°F will cool to 700°F faster than a rotor at 700°F will cool to 600°F. Because of this, it is usually better to err on the side of more drilling rather than less. Just don't go overboard.