OMG..... another bucket!!!!!

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Yup.......... another bucket. At least this one is not a bottom As you can see the damage is pretty clear......... so we'll be removing the old ears and fabing up new ones. The original ears are 1" thick, the customer wants to go with 1.25", whatever he wants. First step is to remove the old ears. This is actually a pretty involved process, things are not always built as they seem.The 1.25" plate is here... I can take a break from grinding and cut the new ear plates. After I draw up a template I head to the burning table. This really is a handy machine.When all is said and done I have 2 new plates cut the same.Next I have to turn up some pin bosses/ spacers to weld to the new ear plates before I weld the plates to the bucket.... I'll continue as I make progress..Thanks for looking..... If you're tired of seeing this stuff let me know....Last edited by lorenzo; 05-08-2007 at 06:27 PM._________________Chris
Reply:You 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:so far so good were are the rest of the pic's?ChuckASME Pressure Vessel welder
Reply:We have to change your handle to "the bucket man"Looks really good.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Lookin' good Chris.Man, I would love to have one of those burning tables. A friend of mine had one setup with plasma but he moved too far away for me to borrow it.  Keep posting, I love seeing this type of work!!- Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:Always good to see that heavy metal. We like heavy metal!John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Quick question, what process was used to remove the old ears? Looks like arc gouging?
Reply:Yeh, don't stop the presses. Keep this stuff comin. It's years worth of experience in a single thread. It's stuff a guy like me would be lucky to see in action  let alone ever get to participate in. Much appreciated, even tho there is little comment sometimes.
Reply:LOLI like the size of the fire extinguisher you got in the left part of the first pic...Nice job! is the burning table CNC?My Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:Originally Posted by elvergonis the burning table CNC?
Reply:Originally Posted by elvergonLOLI like the size of the fire extinguisher you got in the left part of the first pic...Nice job! is the burning table CNC?
Reply:Makes me wonder what caused the failure in the first place.  I know there had to be alot of stress to cause this, but was there some kind of "defect" or "stress riser" that acted as a fracture initiation point?
Reply:Originally Posted by pulserMakes me wonder what caused the failure in the first place.  I know there had to be alot of stress to cause this, but was there some kind of "defect" or "stress riser" that acted as a fracture initiation point?
Reply:Here is the pic.... the arrows point to the spots that the chevron pointed._________________Chris
Reply:Neat pictures for sure..........any ideas what the weight of those cutouts?.........and the bucket?
Reply:That's a good view of the bucket.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Good stuf there Lorenzo, at elast this time is wasn't another bottom replacement, that would just get monotonous. Looks like that bucket could use a new cutting edge and a few other bits of hardfacing too.
Reply:Oh boy Lorenzo I think your customer is going to tear the bucket up now that the ears are beefed up, maybe a little inspection may be in need to help keep from RTD (Running To Destruction) lol. Keep up the good work!
Reply:Hey everyone, not too much to post but this is where I'm at. This part of the repair will be finished tomorrow..... if all goes well. Instead of turning up the pin bosses I just cut them from the 1-1/4" plate I cut the ears from. Welded them to the plates and then straightened the plates in the press... yes even 1-1/4" plate distorts. Then I use my table to tack, set the spread and square up the ears... welding a spacer in place to hold the dimensions....After that I can locate the ear assembly onto the bucket.....After the assembly is located it's really just time to start closing her up..... some good sound tacks and I lay in the weld for the joints that will be beneath the cover plates. The center cover plate was in place and welded with the first pass before I left today so tomorrow I will only have to focus on the actual welding._________________Chris
Reply:HEY!   You CHEATED!!!    What's with the Burn Table?????   You should hand cut, and grind the ears to match like I have to.  Now you are just showing off....      However, I must say as always, very nice work there!  ~JacksonI'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:Originally Posted by zapsterYou get all the fun jobs.. ...zap!
Reply:Originally Posted by Hammack_WeldingHEY!   You CHEATED!!!    What's with the Burn Table?????   You should hand cut, and grind the ears to match like I have to.  Now you are just showing off....      However, I must say as always, very nice work there!  ~Jackson
Reply:Hey Zap. you need a new saying.
Reply:Thanks for the heavy duty welding thread. I would like to try sub-arc, or full spray on material like that, just to say I did it!!! That is pretty awesome stuff. I am amazed when I see 1/2" steel tear apart. The force to wreck 1" has got to be pretty damn powerful!
Reply:That's beautiful work right there....I'd kill to get one of those burn tables...It looks like those parts were machined that way!I hope to be that good one day.21st Century Mountain ManIt's done!!!!!!! Well just about, but 99% of the welding is. I will just have to weld on the pin keeper collars when we are done boring the ears.So here it is.........Will continue in next post..........._________________Chris
Reply:That's it for the ear portion of the repair. I also had to repair a few cracks in the corners and add some brackets to give a little strength, relieving some wear on the corners as well.And ................ yup I guess it wouldn't be a repair for me if I didn't have to touch the floor.  Had to weld in a wear bar where the floor had popped up and ripped open. Well thanks for lookingLast edited by lorenzo; 05-15-2007 at 05:03 PM._________________Chris
Reply:WOW! Being a office-working, weekend-loving gearhead, I just love stopping by and looking at all these projects. What awesome work!!!I'm just hoping some day I can learn to lay-down a half-decent, consistent bead with my mig....For now I will just keep stopping by and dreaming...Weekend MigBackyard MechanicWelder: DECASTAR 150E, Wire Feed w/ Gas Potential (not currently using gas)
Reply:Nice job Chris..Did you use it as a "toss around toy" to get ready for the Mud Bowl?? ...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:Thanks guys, just to give a little additional info........ There are 6 passes for each side of the ear to bucket joint...The pin bosses are 3 passes each...I ran 3 passes on each of the 90* clips...All of the covers, 2 sides, 1 center are 2 passes...All of the welding was done in the flat or vertical up position..._________________Chris
Reply:Excellent job.  Great stuff.When I didn't see any bucket pics for a short time, I started to miss it.  Thanks for posting this project.Whatever you work on next, keep 'em coming.
Reply:Wow!  What a great job.  I'm really impressed!
Reply:that looks awesome Chris!i wish i had access to one of those holodeck tables!!!! (and your ability!!)
Reply:Looks good!! I used to build new HEX (Heavy EXcavator) buckets. We lost them to Mexico and now they are built in Waco, TX using robotics. I'd love to post a few pics but the company frowns upon that sort of thing. No cameras allowed in the shop.Always looking for another old VW, especially in the southeast.
Reply:Originally Posted by lorenzoYes Carbon Arc Gouging is what I use to dismantle the bucket....