Cast Iron Repair - Brake Bracket

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I do alot of repair welding for several of the local tractor and implement dealers and farmers.  So I get considerable amount cast iron repairs.Since we have been discussing cast iron alot lately.  Here is one I did over the weekend.Picture 1 is as received.Picture 2 is sand blasted the broken piece was missing. So I decided the best repair was to weld the ear solid. Face mill both sides and redrill.Picture 3 is partially welded.Picture 4 Completely welded, it cooled in a welding blanket while I did another job.Picture 5 Completely weld flip side.Note: On both the front face and back face I welded 2 layers of Ni99 rod this is needed to make sure your material is machinable. Although this makes for more material to machine off.  If you only weld one layer it will often be too hard to machine. 1/16" Rod at 60 amps.Picture 6 Blasted again.Picture 7 First side set up for facemilling, I used a roughing endmill with a large corner radius for corner security. I also used a small machinist's jack to secure the part from the downward thrust of the endmill. The thrust is created by the larger corner radius. It worked well. HSS end mill at ~100 spfm.Picture 8 Is the opposite side.Picture 9 Drilling out the holes, very slow in case I hit a hard spot, ~125 rpm and 0.001" per rev feed.Picture 10 Finished part.Last edited by Shade Tree Welder; 01-14-2008 at 08:21 PM.Ron ShopFloorTalk Millermatic 350P, M-25, M-40 gunsDynasty 300DX, Coolmate 3, Crafter CS-310 TorchTrailblazer 302, 12RC, WC-2430A spoolgunSpectrum 2050Thermal Arc Plasma Welder PS-3000/WC-100B
Reply:Nice job, better than new!HH 187Miller Bluestar1EAHP AlphaTig 200X
Reply:very nice jobChuckASME Pressure Vessel welder
Reply:Professional!David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Excellent job - step by step repair. The sandblasting really takes the cake.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:nice work
Reply:Nice work Ron.
Reply:Top Notch!I gotttttta get a milling machine!  I take it that the parts are either no longer available or a lot more expensive than your repair costs??Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:Originally Posted by Joker11I gotttttta get a milling machine!
Reply:great work how much an hour do charge
Reply:Would brazig it be stronger or less brittle? Looks good.
Reply:Shade Tree, That is a very nice repair. For sure that bracket is not grey iron, it is probably either ductile or cast steel. The customer probably wouldn't appreciate it; but it would be interesting to give it a spark test, or a nip with a torch.I know I've seen that bracket before. Maybe it's a Kelsey-Hayes truck brake anchor?
Reply:Originally Posted by welderman1Would brazing it be stronger or less brittle?
Reply:Originally Posted by denrepShade Tree, That is a very nice repair.
Reply:Originally Posted by Shade Tree Welder  And the facture was typical of cast irons, no deformation like you would see with cast steel....They could not find a new one...