Can Ya Please Lengthen This By 4 Inches?..

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OK..Here we go...I have a roller that I need to add 4 inches to the length to...This thing is HEAVY!!!!10.150 finish dia and they now want it 67" long.. they want to make a rubber covered idler roller for cardboard transportation in the assy line..Too short as it is so here is where I come into play...We did not know how this was put together because we did not make it...So I have to dig the head out of one side then extend the face and then make a new head...Seems easy enough right?..Haaa Haaa not so fast...2" wall thickness with solid heads as it sat..The customer took this out of service years ago..it used to be a upper press roller therfore all the weight..But now the weight is not a problem because it will be a lower roller and pillow bearings will be used...so...Let get started with some pics...Roller before surgery..Tube for the extension..Oh Oh..Balancing plugs..After MUCH turning and broken toolbits here is what is left..New tube end after machining..I gave it .005 shrink..The next set of pics will show things a little better..Next post......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:As we continue..Here is the tube end installed..Inside depth..Weld inside..Outside weld edge..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:Outside weld pass 1I don't know what happened to outside pass 2...3 headed journal .006 shrink to shaft.Set up..Welds..Tomorrow I will attempt to marry these together..This should be fun..Until then...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:Cool.Plans for rebalancing?MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Awesome job brother! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by duaneb55Cool.Plans for rebalancing?
Reply:Originally Posted by weldermikeAwesome job brother!
Reply:Yep you get all the fun jobsBut you do good workBacked 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:Originally Posted by duaneb55Cool.Plans for rebalancing?
Reply:Originally Posted by MondoShip it off to Lindskog up in Boxboro?- Mondo
Reply:Oh, I thought you had a personal problem.   Nice job on the real project.
Reply:Originally Posted by BD1Oh, I thought you had a personal problem.
Reply:I'm amazed there hasn't been a "that's what she said" post yet. Nice welds!Weld on!"I fully know my place in life, and it's behind a welding helmet...." - Jesse JamesIG: @weldakota
Reply:Originally Posted by zapsterNaaaaI don't think so..This will be ssssllllloooowwwwww speed if anything...BUT if it has to be balanced THEY will do it....zap!
Reply:Originally Posted by duaneb55If slow speed probably no problem but then that would depend on how slow is slow. If it were necessary I was thinking driveline shop.  1810 series joints have close to a 10" swing so I would think a good shop should be able to accommodate.Looking forward to seeing tomorrows work.
Reply:Read the title and instantly thought "that's what she said"
Reply:Originally Posted by zapsterWhen I get to journal finishing I will spin it @ 500..Fast as she goes..If it don't make the machine jump up and down.......
Reply:Nice photos... and, welds ain't bad, either.  Dang, it must be sooooo rewarding to have skills to be able to stretch steel like that.
Reply:It's always the highlight for me on visiting this site when I see your work. Well done and the welds are second to none. As always fantastic work my friend. Miller 302 Trailblazer/Custom TrailerMillermatic 350P/Spool gunMillermatic 252Miller Spectrum 875Miller Dynasty200DxHypertherm Powermax 85Tracker CNC 4X8 Pro Table (Down Draft)Visit us @ www.specialtyrepairscustommods.com
Reply:Originally Posted by zapsterThey just balance cranks don't they?I have not been there in 20 years!...zap!
Reply:That's really amazing work Zap.   I can't help but wonder how you quote on a job like this, given the number of unknowns going in.
Reply:According to my careful calculations, the aproximate weight of that shaft to start, not including spindle or journal ends and allowing that it is hollow with 2" wall thickness....6,727.8 lbs assuming mild steel at .283lbs/cu in.Watch yer toes!Zapster:  What's the capacity of the hoists on that gantry?- MondoMember, AWSLincoln ProMIG 140Lincoln AC TombstoneCraftsman Lathe 12 x 24 c1935Atlas MFC Horizontal MillCraftsman Commercial Lathe 12 x 36 c1970- - - I'll just keep on keepin' on.
Reply:OK as we continue..After letting the tube cool overnight I finished the bores...Now on to the head..Head machined..Heat tube...30 min...You MUST get this hot enough to shrink the head in the FIRST time because there are NO second trys at this..I gave the rear head .005 shrink and the 2 front heads .008...Installed and let cool to grip heads..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:Now it's time to weld..sideways..End welded..Weld..Now for the intricate stuff...The end not replaced has a centerhole that runs dead nuts so we use that and grab the replaced journal in the chuck..Now indicate in your STEADY REST SPOT that was used during boring to zero..Now move the indicator to the replaced journal and find the low spot and set your indicator to zero..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:Wow. Beautiful work, Zap.Motorboating...in the Cleavage of the TetonsAs we get closer to the finish line...After finding the low spot on the replaced end turn the chuck 180 and see how she runs...003...AWESOME!Almost PERFECT!Now turn the replaced tube while still near the chuck..The end we did not replace was 3.000 and the print is now calling for 2.9375 so lets turn that now...Journal finished..Now turn roller end for end and DO NOT FORGET THE BRASS RING!!!One more time......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:OK, now I get the idea behind the three headed journal.  Brilliant!Patiently waiting for "Next".MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Finishing up for today..Now put the steady rest back where your turned spot is and put the journal in the chuck and indicate to zero again then put in your new centerhole and finish..BUT!!This is still hot so we will finish that end in the A.M.Finish it now and it will be .003-.004 UNDERSIZE and that will ruin your dayFor laffs here is the "print" I was going by..Finish tomorrow.Until then..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:Great work man, very very cool!  Time for a well deserved beer break. I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Here is a test...Study the print and tell me what's incorrect.Let's see how good you are....I found it right off the bat but that's my job...And NO it's not the word THREADS.......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:Originally Posted by zapsterHere is a test...Study the print and tell me what's incorrect.Let's see how good you are....I found it right off the bat but that's my job...And NO it's not the word THREADS.......zap!
Reply:The overall length and the center section length are off by an inchMiller Syncrowave 180Miller 211 w/ spool-gunLincoln Ac/Dc buzzboxCutmaster 38 plasmaVictor,Smith's,and Craftsman (Harris) O/A torches.DeWalt Multi cutterFiber Metal helmets(old school)Enough Snap-On to be a dealer
Reply:Yep!Some "Engineer" eh?Leave the untouched end as is because it came in at 6" anyway......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:Zap do you ever you liquid nitrogen to shrink parts instead of heating to expand? I have made similar rollers in the past this way I like freezing for this much better. Started using it when had to make some pieces that had to be shrunk and inserted into a thordon bushing. Just curious.
Reply:I see the extension is a larger diameter that the original drum spec of 10.150". The print also notes "please match existing core". So the question is - How will you machine down the new collar without loosing all strength?Gizzmo
Reply:Originally Posted by ChrisA7164The overall length and the center section length are off by an inch
Reply:Originally Posted by gizzmoI see the extension is a larger diameter that the original drum spec of 10.150". The print also notes "please match existing core". So the question is - How will you machine down the new collar without loosing all strength?Gizzmo
Reply:since the roller is gonna be covered with 3/4" thick silicone rubber, balancing this thing would be like putting cream cheese on horseschitt..
Reply:Originally Posted by gizzmoI see the extension is a larger diameter that the original drum spec of 10.150". The print also notes "please match existing core". So the question is - How will you machine down the new collar without loosing all strength?Gizzmo
Reply:Originally Posted by zapsterHere is a test...Study the print and tell me what's incorrect.Let's see how good you are....I found it right off the bat but that's my job...And NO it's not the word THREADS.......zap!
Reply:Originally Posted by rideitWell, you spelled 'loses' wrong in your signature thingy. Do I get a prize?
Reply:Well, I'll have to check the metallurgy, but I suppose the molecules might in fact 'loosen up' when melted!Motorboating...in the Cleavage of the Tetons
Reply:Great project. I really enjoyed watching it progress.
Reply:Originally Posted by welderjGreat project. I really enjoyed watching it progress.
Reply:Don't know how I missed this thread yesterday. You do get all the fun jobs. Great execution once again.
Reply:how do they get the rubber on the roller? Its not like they can shrink fit it onto the metal, is it?miller syncrowave 250hobart handler 140home made 400 amp engine driven in progress...
Reply:Originally Posted by zapsterYep!Some "Engineer" eh?Leave the untouched end as is because it came in at 6" anyway......zap!