It will really depend on the rotor, Some can be turned down and smoothed out and have a minimum thickness, others will go past the point. I have had the groves in rotors before and simply put on new pads, yes they might get a little quirky till they are bedded but will stop and work fine. It's only when they are warped do I worry about turning it or replacing them. No you would only need to replace the one rotor that is bad if it is, What make and model vehicle? Trucks are more forgiving than cars and are more robust than imports!
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