Forklift Counterweight:

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Here is a little project I've been working with for seemingly much too long.... The cylinders needed repacked so I pulled the mast off complete, broke it down into individual parts so to replace anything worn, and have run into another problem. The counterweight on the back has a very large casting flaw that Hyster apparently chose to caulk full of some type of urethane fill to bridge the gap this void would leave between panels:I would like to repair this area but don't know if it it cast steel, or cast iron at this time. I'll take a grinder to it to find out. I'm planning to weld it up with 7014 if steel straight away, and if cast iron, first install a base of nickel rod then build up with 7014. I don't really know of any other way to build it up if not just notching it out rectangular then welding in a piece of stock? From the photos it can be seen how massive the casting void was and I'd have not seen it had it not been for trace rust leeching out from under the filler caulk.I'm open for suggestions should anyone have a better way.Thanks, Attached ImagesSlobPurveyor of intimate unparalleled knowledge of nothing about everything.Oh yeah, also an unabashed internet "Troll" too.....
Reply:I actually thought about that but would use a fiber/metal based material as it's stronger than plain polyester filler. The edges are not in contact with anything and do not rub at all so in reality that would work.Thanks,SlobPurveyor of intimate unparalleled knowledge of nothing about everything.Oh yeah, also an unabashed internet "Troll" too.....
Reply:Just remember to apply bondo in thin coats. Too thick at once and it will crack... like welding cold cast. GravelThe difference between theory and practice is that in theory there is no difference.
Reply:From the photos it can be seen how massive the casting void was
Reply:Originally Posted by 12345678910Hyperbole ?It doesn't look structural.It's a forklift not a Ferrari, I'd say who cares ?
Reply:I wouldn't weld it and create stress in the casting for (my opinion) no good reason. I would use body filler, epoxy or iron cement. If you are concerned that the repair might fall out, use a die grinder to create a dovetail to give it a mechanical attachment as well. Smooth it up and paint it and then forget it.---Meltedmetal
Reply:Originally Posted by MeltedmetalI wouldn't weld it and create stress in the casting for (my opinion) no good reason. I would use body filler, epoxy or iron cement. If you are concerned that the repair might fall out, use a die grinder to create a dovetail to give it a mechanical attachment as well. Smooth it up and paint it and then forget it.---Meltedmetal
Reply:Since the purpose of this thing was to add weight, have you considered the grand-daddy of all fillers, melted lead? You'd have to be careful about adding too much heat to that casting though.250 amp Miller DialArc AC/DC StickF-225 amp Forney AC Stick230 amp Sears AC StickLincoln 180C MIGVictor Medalist 350 O/ACut 50 PlasmaLes
Reply:I don't think I have seen a forktruck counterweight that wasn't full of plastic filler in twenty years of factory work. They all do it, and have for decades. Mud it up and paint it.-Spike
Reply:Originally Posted by Spike440I don't think I have seen a forktruck counterweight that wasn't full of plastic filler in twenty years of factory work. They all do it, and have for decades. Mud it up and paint it.-Spike
Reply:I was surprised but this is the first forklift truck I've owned and had to work on. Others have been leased units with contracted maintenance. I was surprised at the size of the voids myself and having been around foundry work many years ago, found this type of production work quite lousy. Anything coming out of the moulds looking like this would be liquid either the next shift, or day at the latest to be recast. It's been a real informative thread for me and thanks for all's input.SlobPurveyor of intimate unparalleled knowledge of nothing about everything.Oh yeah, also an unabashed internet "Troll" too.....
Reply:usually they are cast steel filled with cast lead some are cast ironVantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.