Just When You Thought You've "Seen It All"...

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Just goes to show you'll never see it all.. Boss brought in 2 Aluminum rollers for turning and to fix one journal..Rollers..He asked Me what I want to do with this..."Well I'm not wasting time trying to actually weld that so I'll fab up a sleeve for it instead"...Good thing I did not even attempt to weld it..Just turning this down was a headache...Good greif!! What the......I need My magnet....Yup thats steel..along with the aluminum...all in one?????Thats right friends..Somebody somewhere "welded" this aluminum journal with steel... It chewed up a hi-speed tool bit in the process..Now you have to get underneeth it to get rid of it... Here's what's left...Now its just the standard sleeve it and weld it...I had no intention of posting a little journal repair..You've seen enough..But this one...I had to show everyone what happens when this is attempted..So dont attempt it.. Man!!!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:Hahahaa...yuck! That looks like a messy yet strangely "fun" job. John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Originally Posted by MicroZoneHahahaa...yuck! That looks like a messy yet strangely "fun" job.
Reply:Looks like it has seen some salt in its life.Disclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:Maybe hitting it first with a grinder might have saved you that high speed bit. Just a thought for next time.
Reply:Wow!  And I though JB welded material was a fun refix.Common sense in an uncommon degree is what the world calls wisdom.
Reply:Wow...I didn't know that you could weld Aluminum with steel....that was disgusting   Good job on the repair Zap!
Reply:Originally Posted by TozziWeldingLooks like it has seen some salt in its life.
Reply:My guess is the "maintainence" dept fixed it the first time.  Looks good as new now.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by David RLooks good as new now.
Reply:Originally Posted by PookieHow do you know?I didn't see the finished product.
Reply:Ok now here are the done pics.. Journal welded..Journal finished..Roller finished..Roller finish..Nice and shiney huh?Best part about this type of job is it takes 2 hrs to go from end to end..And all I can do is sit there and listen to it..Takes 2 passes to finish..Finish diameter 12.250 with only .0005 taper end to end..Then the polishing pass..Thats top secret... ...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:One more for the alchemist cook book.NICE JOB!!!Attachment 11219Last edited by denrep; 02-22-2009 at 07:45 PM.
Reply:Where's the dime?   And sheesh, you had half a thou taper end-to-end?   Man those rollers looked really bad when they came in.  And those shaft stubs were horrible!  Pocked and steel embedded, I wasn't sure if you were just going to cut them off and put new end-plates and shafts on the rollers!Shafts look good, roller surfaces look good, now you have to make the end-plates look good to match.
Reply:I love the smell of freshly lathed material ! Aaaaah ! John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Very nice work as always.  Did you use a follower rest or was the roller rigid enough without it? ~JacksonI'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:Originally Posted by Hammack_WeldingVery nice work as always.  Did you use a follower rest or was the roller rigid enough without it? ~Jackson
Reply:I have a friend that uses a similar method, just curious what yours was.  Always interesting what tricks everyone has up there sleeve when it comes to metal working.I'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......