Excavator Rod Assy....

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Excavator rod came in for a rod replacement...The piston end was snapped off...Customer supplied the new rod..I had to transfer the eye end from the old to the new and turn and thread the piston end....Rod...5" Hard Chromed 68" long...Piston surface finish 2.774...Thread....2.500 - 4 .....Bored the end 4.5 deep..4.456 ID..Eye was turned 4.460 OD...4.45 long...I used a brass ring for the ground clamp to bite into...I was not going to mar my nice finished surface or threads...On with the pics...Rod assy..Ground...Groove..First pass..Second pass..Next!......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Measurements sound close to a Cat 345 series.SlobPurveyor of intimate unparalleled knowledge of nothing about everything.Oh yeah, also an unabashed internet "Troll" too.....
Reply:As we continue..Last pass..Finished end..Stamp of approval...Welder on kill..3/32" Red...#4 cup..Footpedal in use...Welded while standing up...Ahhhhh my back....1/16" 70S-2...I get all the fun jobs.......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Nice repair. I just ordered some 5" chromed bar yesterday... not cheap. Would it have been feasible to install a stud rather than replacing the whole rod? Or was the rod trashed?
Reply:The rod was salvageable but like I told Irish Fix It one day...Customer gets what customer wants...I don't argue with their decisions anymore.....However the rest of the old rod is ours now......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Very nice save and nice welds, I thought only inverters make pretty welds like that
Reply:Dang you do nice work....Here's an atta boy500:atta boys = 1 : oh crap...Depending on bosses attitudeBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:Shoulda rolled it with 1/4" 7018.It'll need flat bar stiffeners, being that you tigged it...
Reply:And a wash over the top to make it look niceNice fix Zap.
Reply:I have to ask why you didn't cut the old weld off , but welded next to it ,  The third and fourth pics show the orignial weld  ?   gxbxc
Reply:Originally Posted by gxbxcI have to ask why you didn't cut the old weld off , but welded next to it ,  The third and fourth pics show the orignial weld  ?   gxbxc
Reply:Originally Posted by zapsterAs we continue..Last pass......zap!
Reply:nice work zap. a few more years under your belt and you might get that tig thing down pat.i.u.o.e. # 15queens, ny and sunny fla
Reply:Ok  I have never done any  work like that and was wondering the reason for doing it that way . I guess the extra 1/2" to 3/4" wouldn't make any difference unless it was in a two piston set up,
Reply:Curious as to what RPM you are turning the piston at. Are you using carbide to rough and HSS to finish and cut the threads? Also the welds look awesome.
Reply:Originally Posted by EndofabCurious as to what RPM you are turning the piston at. Are you using carbide to rough and HSS to finish and cut the threads? Also the welds look awesome.
Reply:Originally Posted by zapsterBoring RPM 117...Pretty heavy and friction builds heat...Turning 330...Threading 16...Carbide for boring and turning...Crucibal Rex Hi Speed for threading...I grind my own bits......zap!
Reply:Looks fantastic! Love the punch mark!12v battery, jumper cables, and a 6013.I only have a facebook page. https://www.facebook.com/pages/VPT/244788508917829
Reply:E'gads man.    I've been involved in quite a bit of heavy hydraulic cylinder repair for the mining industry and I've never seen an eye that size tig welded on before.  More importantly I've never seen one of that size done with any where near that shallow a weld prep.   It'd be my guess that the odds are good you're going to get a second chance at welding that eye back on before long.
Reply:Looking at the heat marks on the shaft prior to welding that bevel, I wonder if the shaft was bored then heat shrunk onto a turned down portion of the eye. Zap does a lot of interference fit joints like that..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by DSWLooking at the heat marks on the shaft prior to welding that bevel, I wonder if the shaft was bored then heat shrunk onto a turned down portion of the eye. Zap does a lot of interference fit joints like that.
Reply:It ain't going nowhere.My success rating on this type repair is 100% and I plan on keeping it that way....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:I'm curious why tig rather than 7018 or some other rod?Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw
Reply:Hey man great save. Could see it a lot better on my computer than earlier on my phone. You do some nice work. Now we just gotta get you into some stick welding. I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Don't get sore with the messenger, but I'm going to say "maybe" "maybe not" depending on the application.For a cylinder seeing strictly -or nearly so- compressive loads in line with the bore, maybe.For a cylinder seeing all sorts of dynamics, including loading from other cylinders and sources, I have to say probably not.Here's why - The cylinder was designed with a 5" rod because the application needs that mass. If less were enough then that would have been specified instead of 5 inch rod.Here's what the repair changed - By "plugging" the old eye to the new rod, lots of area has been lost. Boring a 4" hole in a 5" rod leaves essentially a 5" x 1/4" wall tube on the rod's end. That is approximately what is now connecting the eye to the rod, 1/4" wall tube. Compared to the original design connecting the eye with 1/4" wall tube loads significantly less material.So the change from OE design will maybe be okay   for strictly compressive loading. And maybe not okay for the wild dynamics an excavator can see.I vote to make the owner aware of the change and let her decide.Last edited by denrep; 10-10-2014 at 06:37 PM.4 1/2 dia 4 1/2 long with 4 thousands interference fit and then welded, I don't think it is going anywhere. This is a common method for repairs of this nature.Mike
Reply:Originally Posted by leightrepairs4 1/2 dia 4 1/2 long...
Reply:I am so glad everyone is so concerned....If it fails you guys will be the fourth in line for the news..Customer... 1Boss...2Me... 3You...4Fair enough?...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:More than fair enough as far as forum readers are concerned.Zap, you know I'm no finger shaker, but on this one  I'd strongly suggest to put the cards on the table and let someone else decide what to do.In my humble opinion the rod is now at a fraction of its original strength. My belief is based on considering the described air-gap between the plug's end and bored hole's bottom, which essentially bisects a 5" solid rod and splices it with 1/4" wall tube. And again the described boring which left only the  thin 1/4" wall surrounding the plug. This time, the problem with "let's just try it" is that when a large cylinder like that fails the consequences can be disastrous. I'll limit speculations to only a failed cylinder itself. First thing, during the course of it's eye failing a cylinder's rod is often damaged beyond repair. Next up, a failed heavy cylinder can drop, and if to a hard landing, it can be with enough force to ruin barrel and rod. Thirdly, a falling heavy cylinder will often destroy its "plumbing" adding great cost to a repair. Lastly, often during failure, while an operator is still trying to grasp what's happening a severed large hose can pass a LOT of oil.So again, IMHO the concerns should be passed up hill before deciding to just run it.
Reply:Not a naysayer either but denrep has a very strong argument.
Reply:Nice repair! Im sure it will out live the machine.
Reply:It is a beautiful weld, but I have worked this industry, and I can tell you it will break again. Weather it is Zap's repair or not, if they broke it once, they will break it againBruce DeLaetHeavy Equipment Mechanic and Welder1948 SA-200 short hood1949 LincWelder 1801963 SA-200 red faceMiller S-32-P