Good Lord!!!!

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Customer brought in another roller...Says one journal is .020 under and the end of the tube weld might be cracked..So...I set it up in the lathe to have a look see..When I indicated the tube in to zero with center in the other end then it became evident...The journal in the chuck was running out .165 while the tube was zero...The other end with the center..The journal was zero and the tube was out .200!!!In other words this is NO GOOD as is..Ain't no way this is a simple repair.So the back head had to go.Now it gets interesting.Anyone here ever weld OVER taper lock bushings??Well someone did on both ends...and we did not know this until the head removal was underway...I cut the journal off and drilled and bored out the shaft until I got it to undo itself from what was left of the bushing.Then I turned the roller end for end and proceeded to turn the weld off the bushing until the shaft came out.Now that the shaft is gone I need to bore both ends to install double heads on both ends.Pics tell the tale.Welded bushing...Hackers.Yep..I found the set screws..Carbide inserts take a beating..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:After turning the weld off the bushings the shaft came out..Shaft end from boring out side 1...Here is what is left of the welded in bushing..Well Well...Lookie what I found inside the tube..End all bored and done..Monday I have to bore out the other end that I started with and make 2 new heads...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:Crunchy, Crunchy. You do get all the fun jobs. Despite all your years at the shop are you still the low man?
Reply:Not sure the stuff stuck to the bushings qualified as "welds"...you were being kind Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Another fun job!  You seem to have a monopoly on fun jobs.  I'm sending my complaint to the FTC!  - 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:The worst part of the whole deal is that we have to wait until Monday to see the out come.
Reply:This stuff goes so over my head I feel like I need to take a fab and machining class. I'm just a pipe welder.
Reply:You are really hard on yourself getting all the fun jobs.   I was thinking that you guys with the lathes really have some great skills in  repairing some of the junk other folks cover up.    Cant wait to see the rest of the story. richey
Reply:- worker #Z "Hey boss, these shaft collars keep coming loose. What should I do?"- boss "Just weld them up.  That'll hold them."  The best laid schemes ... Gang oft agley ...
Reply:Originally Posted by MoonRise- worker #Z "Hey boss, these shaft collars keep coming loose. What should I do?"- boss "Just weld them up.  That'll hold them."
Reply:I thought all the "No Speaks" were down in my area..lol  Miller 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:So. Zap, what part of Costa Rica are you in ? Muy bueno trabajo !Bubble gumTooth pixDuct tapeBlack glueGBMF hammerScrew gun --bad battery (see above)
Reply:Well that definitely looks like a fun job!
Reply:I had a belt conveyor roller brought to me welded on the taper locks, broke at the welds. Shaft ends were all screwed up as well. After cutting all the crap apart and getting the ends off the shaft was in 2 pieces. Apparentlly the (engineers) who made this roll shortened this roll by cutting a piece out of the center and rewelding it. They never sleeved the shaft or anything. Who would of thought that it might have a little runout!Miller xmt304,  Miller S22 p12, Miier Maxstar SD, Miller 252 w 30A, Miller super32p12, Lincoln Ranger 9, Thermal Arc 181I with spoolgun, Hypertherm 10000 ,Smith torches. Esab 161lts miniarc.
Reply:Despite all your years at the shop are you still the low man?No he's the yo man can you fix this thing.Zap, I really like to watch a master at work, Thanks for sharing it with us.www.georgesplasmacuttershop.comPlasma Cutter and Welder Sales and Repairs--Ebay storeTec.Mo. Dealer Consumables for the PT and IPT torch's
Reply:i give you tons of credit,  most of these things i would just tell them it would be cheeper to make a new one.Vantage 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.
Reply:Ok, what happened? www.georgesplasmacuttershop.comPlasma Cutter and Welder Sales and Repairs--Ebay storeTec.Mo. Dealer Consumables for the PT and IPT torch's
Reply:Originally Posted by zapsterCustomer brought in another roller...Anyone here ever weld OVER taper lock bushings??Well someone did on both ends...and we did not know this until the head removal was underway...Now that the shaft is gone I need to bore both ends to install double heads on both ends.Welded bushing...Hackers.Yep..I found the set screws.....zap!
Reply:Some epoxy will fix.that up.
Reply:Originally Posted by mechanic416Ok, what happened?
Reply:Heads turned .010 bigger than the tube bore..Heat tube install heads to edge..Make sure you have your weld prep done first...!Welded.Now...Set up the steady rest where the original spots are..(Because there are no centerholes drilled yet..)Turn a new steady rest spot on the JOURNAL near the chuck..Why?Because after heating and welding the spots on the tube are not very round anymore..Most times they have .003-.005 out of round bumps in them now so if you were to put in your centerholes they would have the same runout in them so after it's all said and done you will have .003-.005 egg shaped journals and that's no good at all..Continued.....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:This is when having 2 steady rests come in very handy..Flip the roller end for end..Using the old spots for reference set up the other rest on the new spot on the journal...NOW remove the first rest from service and use the journal spot for finishing..It is perfectly round so everything from now on will be perfectly round!Do both ends the same then finish as usual..Centerdrill/Face to length..Finish to spec.After both journals were done I took a cleaning chip off the roller O.D. so the tube will be in balance..On press rollers I use the shrink fit on everything...I have seen heads drilled and reamed to size and they just slide on the shafts and depend on the weld only to hold them..Not the best way to do this so heat and shrink insures you that there is nothing that can loosen up over time with all that pressure on them..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:Well done as always  Thanks for the advice on using the second rest to keep things straight www.georgesplasmacuttershop.comPlasma Cutter and Welder Sales and Repairs--Ebay storeTec.Mo. Dealer Consumables for the PT and IPT torch's
Reply:Zap, Are any of those rollers made from solid stock ? Seems easier than making heads on the inside. But I know zilch about machining. I try to pick up stuff from MarkBall2 but usually it goes over my head.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 Joker11Zap, Are any of those rollers made from solid stock ? Seems easier than making heads on the inside. But I know zilch about machining. I try to pick up stuff from MarkBall2 but usually it goes over my head.A) You do nice work!B) What type of machine are these used in,what do they roll?