Some shots of the progress on the spray rig (as promised)

admin

Well the last week (actually a little more) has had the spray rig as the primary focus. Between interruptions and gotta have them now projects we've actually managed some progress. It's back on four legs now (though looks like we'll have to pull another leg out next week). I didn't manage to get a full set of step by step pics for everything but I did get a good number of pics even if there are gaps.  I stated in the other post about having to redo the bearing design of the swing arms. The original bearings shown there in thin bosses on the inner part just wasn't strong enough. I decided to go with hardened steel bushings on hardened steel shaft. I also decided to move the bearings out on the swing arm instead of having them inside the center boss. This moved the leverage the bearing have on holding the wheel straight. In fact it nearly doubled the leverage thus halving both the force applied to the bearings and the amount of wheel movement that wear would cause. In order to do that I had to add bosses to the swing arms. In the first pic you can see me boring one of the swing arms in order to get the holes the same size and lined up for installing the bosses. I was forced to bore this one because last year we had bored the big hole in this swing arm in order to compensate for wear (we made a larger diameter sliding bush to tension the original bearings at the same time). The second pic shows me drilling the second swing arm. I drilled the first one the same way but had to take it out bigger than the 2 1/4" which is the largest drill bit I have.  The third pics shows the new bosses welded in place on one of the swing arms. I managed to get them welded to where the alignment shaft would slide through freely. This was tricky considering that the sides of the plate where not straight as shown in the fourth pic (actually that first one was worse than the second).   The only thing I could find for hardened steel bushings in the right size was drill bushings. They didn't have any clearance to allow for a good press fit and and misalignment. Thus we had to grind out the ID some as well as add grease grooves. The last pic on this post shows the ID grinding in my poor mans method.  Many more pics to come. Attached ImagesMillermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:Here's the finished bushings. The second pics shows them installed in the swing arm with grease zerts ready to go.  The third shot shows the center portion with it's new bore and the hardened steel shafts that go in it.  Once we got done with the lower parts it was time to pay attention to some cracks in the axles themselves. At first it didn't look to bad but once we pulled them apart and started cleaning it turned out to be bad. Bad enough that I decided we had to start over. It's hard to see in the pics but the crack goes nearly all the way from top to bottom. Attached ImagesMillermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:Here's the rough cut new plates to replace the original. I decided that to go a different way than the factory for reinforcing the plate. I didn't like the little straps just wrapped around the tube. It allowed for to much flex. As you can see in the second and third pics I doubled the plate as well as added a couple of gussets in the highest stress area. I also added three more bolts bringing the bolts in closer to the axle to reduce the amount of flex. Ignore the two extra holes. I was looking at the other side of the machine when I measured for them not realizing that they had different offsets on the outside plates from one side to the other.   The fourth pic shows the outside plate after finishing. It to had started to crack from the factory gusset at the bottom right up through where the two new bolts are now. When I started gouging it out I soon had a hole bigger than 1" dia in the plate thus decided to replace that corner of the plate. I also ran into a pretty bad crack at the top so added another gusset there. In the next post there will be pics of the other side so you can see the differences. At the bottom I added a gusset to bring the stress point out to the corner of the plate like it should of been and added a gusset to the pipe as well.  The fifth pic shows how I added the extra holes for the bolts. Attached ImagesMillermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:And now to the other side. These are before and after pics of what I did to fix the other side. You can't see it in the pic but there's a small crack just starting at right hand side of the factory gusset. I ground and welded the crack and then beefed everything up as you can see. Attached ImagesMillermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:Now it's on to the next problem. These are pics of the back axles. As you can see one side has a rather serious problem. I'm still thinking on how I'm going to fix that one. Not much room for gussets there.  I'll get some more pics of the overall assemblies when there's daylight. Attached ImagesLast edited by irish fixit; 09-10-2011 at 10:22 PM.Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:Sorry, I'm new here, but what kind of truck is this? Interesting stuff though. I enjoy these kind of projects most (and the art stuff like Johnny Pop's)
Reply:Thanks for posting your fixes.Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Originally Posted by macvanceSorry, I'm new here, but what kind of truck is this? Interesting stuff though. I enjoy these kind of projects most (and the art stuff like Johnny Pop's)
Reply:on the next problem i would say a thicker plate and a full pen weld with a 1" plate backing.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:Okay, I'm with you. I know what a spray rig is then. Just never knew what they were actually called. That's a lot of work without a lot of fancy tools. Looks like you're making due with what you have, but you're doing very well.
Reply:Nice work for sure. I love repairing/redesigning something that's broke, Yeah I know I'm a sick puppy LOL.On the back axle. Thinkin' out loud here. What about if you cut the plate off completely 1/4" inch or so behind the origonal plate and make a new out of heavier material 5/8 or 3/4. If you'd still be worried about it breaking weld a short spigot (6" long or so) to the plate and slide it inside the origonal. By using a short spigot you could weld the inside of the tube which wouldn't interfere with sliding in all the way, or you could bevel it. You could also make the plate slightly bigger so it sits on the lip the air bag attaches to, it'll give you a bit more room for gussetts.....Mike
Reply:Looks good. Now that you have it 2x stronger than it was, the ownner thinks he can treat it a little rougfher (4x rougher).  If customer is like some of mine the only time the grease zerks will get used is before it leaves your shop. Seems like equipment built for light duty use is bought by customers that use it heavy duty. Good save.PeterEquipment:2  old paws2  eyes (that don't look so good)1  bad back
Reply:Originally Posted by Dualieon the next problem i would say a thicker plate and a full pen weld with a 1" plate backing.
Reply:That looks like an Apache, around here they are called High Clearance Sprayers. That one is small by today's standards.Nice fix.Leo
Reply:Originally Posted by NVWThat looks like an Apache, around here they are called High Clearance Sprayers. That one is small by today's standards.Nice fix.
Reply:Good job as always Irish!! I always enjoy your posts, you are a true craftsman.
Reply:Thanks.Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:I make a piece that slides up in the tube a ways and then plug weld it in a few places I've essentially reinforced the tube where it's weakest
Reply:Sorry about the delay but it's been super busy around here. Here's the shots I managed to get of the last axle. I meant to get some more after mounting but I was just to busy.  The first shows how I clamped the inside piece to get it to size. I welded it clamped like that with 1/8" 6011 from the inside full length as you can see in the second shot. I then welded it up with 7018 on the outside pretty much full weld.  The third and fourth shot shows it before and after I welded it to the first plate. I then ground it flat and the fifth shot shows after one pass on one side with 5/32" 7018. I filled it out to full weld on the bevel there after that. Then finished the plug welds and added a couple of gussets to the long side of the plate. I also added two gussets to the axle on the other side to try and help it. Attached ImagesMillermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:Better than factory, nice job....Mike
Reply:Thanks. We'll see how long the other side holds up with just extra gussets added.Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm