I was thinking about shims too but I don't think that's the answer for a couple of reasons. First, they are standard equipment on some import cars, but then the notches in the pads are sized to fit over those shims. Your pads are not designed for the extra width the shim would create. Next, once the grooves are already in the knuckle, hard braking could cause the pad to push the shim down into the groove and make another low spot. If the shim crinkles, the pad won't want to move at all.
I didn't look for any such repair method, but if there is something available, my guess would be it would require grinding down the knuckle to make the shim fit while maintaining the old outer dimension.
Something else you might consider is a product used extensively in paper mills called "Belzona". It is mixed like epoxy, spread like glue, then machined just like metal. They use it to build up damaged shafts where they could loose a million dollars per each day the machine is down waiting for a part to come from Germany! I used it to repair the square end of the speedometer cable on my '88 Grand Caravan that I damaged earlier, and it's still working after 80,000 miles. This material can be cut on a lathe just like metal, but it is REAL expensive. It's also available in small packets but I don't know about the cost.
Sunday, May 29th, 2011 AT 9:06 PM