Make Both Sides Match..1 From Inside..1 From Outside..

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I have 3 drive rollers to convert to idler rollers..When I got them the drive side was 4" longer than the sample and had a 1.5" shaft with a key in it..,The other side is just not long enough..So what I did was cut off the drive side shaft to the length it had to be and turned it down to 1.379 for shrinking a new sleeve on it that finishes @ 1.375 ID..Short side was drilled and bored in 1 1/8" and finished @ 1.246 ID..The plug was turned to 1.250...Both ends will end up the same size as the short side..2.187 OD..(Note!) when doing this kind of repair make the shaft .020 bigger than the finish size right near where the weld will be..Easier to fill and clean that way..Pics will make this clearer if you can't figure out what I am doing.Pic 1.. Sample roller..Pic 2.. Long end cut and turned...Pic 3.. Side to extend..Pic 4.. Parts made..Pic.5.. Table holder for shrink fitting..Will explain 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:I used the holder with the hole in it so when shrinking on the new parts gravity will keep them together..IMPORTANT!!!!!After shrinking together you MUST tack them RIGHT AWAY or else when the heated part cools the piece will actually pull away from the shoulder as it cools and then when you weld it the shaft will bend because of the gap..TACK THEM NOW WHILE IT'S STILL RED HOT!!!!!!OK now that that's done..Pic1..Sleeve end on..Pic2..Stub end on..Pic3..Tacked while hot!!!!Tomorrow I will weld and finish these so stay tuned...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:Zap, in all truthfulness, these type of posts by you are fabulous!The special tricks & knowledgeable techniques you apply & share and the photo documentation makes each of these threads a major learning experience for many of us.In honour and respect to your passed-away feisty pal...Thanks Zapster! Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Thanks Rick!One other thing..When doing this with more than one piece it's best to make everything the SAME from the start wherever you decide "Start" is..I have seen others do this same thing and every bore is different and every shaft is different and in the end you don't know what goes to what anymoreAll the same?Everything fits no matter what piece you grab.And that's the "No Brainer" lesson for today....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 zapsterI used the holder with the hole in it so when shrinking on the new parts gravity will keep them together..IMPORTANT!!!!!After shrinking together you MUST tack them RIGHT AWAY or else when the heated part cools the piece will actually pull away from the shoulder as it cools and then when you weld it the shaft will bend because of the gap..TACK THEM NOW WHILE IT'S STILL RED HOT!!!!!!OK now that that's done..Pic1..Sleeve end on..Pic2..Stub end on..Pic3..Tacked while hot!!!!Tomorrow I will weld and finish these so stay tuned...I get all the fun jobs.....zap!
Reply:How much interference are you running?  If you're working with hard materials you have to be real careful about too much interference because you'll crack it as it cools.
Reply:You should write a book Zap.Seriously, you explain things clearly and you photo document things very well. Perhaps even publish an edition in Chinese.........Rick's pic reminded me of one I found amusing.Peace,Mike Attached Images
Reply:Thanks guys..(I miss my cat..BAD)Anyway here are the finish up pics..Pics are in order..Pic 1.. All set up in the positioner..Pic 2.. First pass..Pic 3.. Second cap pass..Pic 4..2 of them ready for the lathe..Pic 5..First step..Centerdrill and face to length..When you get to this step centerdrill and face ALL of them to length so you can lose the steady rest and then it's just indicate and turn..Finish this up 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:OK to finish this up..Pic 1..All set to go without the steady rest in the way..Pic 2..Finished 1 side..All dimentions are perfect!Pic 3..All done and cleaned up the roller body itself..Pic 4..Where was the weld?Well that's that!!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:Originally Posted by 76GMC1500How much interference are you running?  If you're working with hard materials you have to be real careful about too much interference because you'll crack it as it cools.
Reply:Originally Posted by forhireFrom the first post... it appears to be 0.004" Zap, nice work as always. I'm always amazed how well a shrink fit will hold.
Reply:beautiful work!Love the chair by the way....Might as well be comfortable right?...  Miller Dynasty 200Millermatic 211Instagram?.... find me @ WELD_MEDIC
Reply:Originally Posted by zapsterYep. .004 is correct!And to think.....I failed general math 4 straight years in hi school.....zap!
Reply:Originally Posted by tig_21beautiful work!Love the chair by the way....Might as well be comfortable right?...
Reply:Originally Posted by zapsterYes indeedeee!!I spend alot of time there..Mrs. zap's office closed and they made everyone home based employees last year and when the meeting room stuff had to go it was free pickin's for anyone before it was all loaded into a dumpster..Grabbed 3 chairs..2 for the office and 1 for me.Just have to be aware at all times to where the grinding sparks are pointed...I like to fish the tig hoses in thru the back of it and inside the arm rest..You never run it over or have it dragging on the ground like that.....zap!
Reply:Incredible man you do amazing work.