Man! Was This Worn Out...

admin

Another machine chuck to rebuild...This was used way too long and the tube that goes on it ate the shoulder...I DID NOT want to have to put this in a Bridgeport after to save the counterbored holes so it's the 'ol Aluminum Plug trick to the rescue...I try to get as much done around the bore without the plug but when the time comes its plug time..The chuck..The worn in groove...Fill in the groove around the hole as best you can before inserting the plug..Plug inserted..Now stick the tungston out so you can get behind the plug..Next post......zap!Last edited by zapster; 06-03-2010 at 05:27 PM.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:Continued...The welded area after the plug was removed..Another view..The groove all welded up...Close up..The completed chuck after I got the O.D. done...Tomorrow I will machine this to spec and we'll see how good the plug trick works..,,,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:Cool beans.  How many lbs of weld have you added to that thing?  Looking forward to tomorrows picsThe Lord has declared, "This is my work and my glory--to bring to pass the immortality and eternal life of man"  Moses 1:39Link: My name is John, and I am a member of The Church of Jesus Christ of Latter-Day Saints.-- ColdCreekWorks.com --
Reply:Originally Posted by jdh239Cool beans.  How many lbs of weld have you added to that thing?  Looking forward to tomorrows pics
Reply:thats a nice fix right there. i like the plug idea
Reply:That's a fair afternoons work zapster. I use brass and copper around the mig all the time but never thought of it with the tig (always reasoned I could control the puddle well enough, now after further review...). That looks good.Matt
Reply:Hey Zap,Nice repair & super suggestion for the youngsters/newbies to understand the "plugging" technique. Been doing that many years & both spectrums....alum plug for steel & steel plug for alum.DennyComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Thanks guys...Hey there Denny...Good to see you around again...Hows things going?Send me a P/M if you wish.......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:Nice work as usual.I notice you did a really nice, consistent pattern of fairly wide, weaved linear welds, around the circumference to build up the surface.  Being a round part, this seems to be a good application for using a rotary positioner and doing a continuous, spiral circumferential weld build up.  Just curious why you did the build up like you did.
Reply:My biggest concern would be making the assembly concentric.  How are you indicating it before welding?  And do you ever get a bit off when tacking it prior to welding.Forgetting weld procedure, that would be the interesting thing about this repair.I saw the padding on the piece, is this turned to make it true with the center at the OD?I may have to retract the question after taking a second look at the pics.  I might be not looking with the correct eyesCool stuff"Any day above ground is a good day"http://www.farmersamm.com/
Reply:I call that a fix.  Nice job!City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:Originally Posted by pulserNice work as usual.I notice you did a really nice, consistent pattern of fairly wide, weaved linear welds, around the circumference to build up the surface.  Being a round part, this seems to be a good application for using a rotary positioner and doing a continuous, spiral circumferential weld build up.  Just curious why you did the build up like you did.
Reply:Originally Posted by farmersammMy biggest concern would be making the assembly concentric.  How are you indicating it before welding?  And do you ever get a bit off when tacking it prior to welding.Forgetting weld procedure, that would be the interesting thing about this repair.I saw the padding on the piece, is this turned to make it true with the center at the OD?I may have to retract the question after taking a second look at the pics.  I might be not looking with the correct eyesCool stuff
Reply:The (Almost) finished part..All I need to do is deburr the holes and sand/polish the tube O.D.The groove is gone and it runs dead nuts now..Just like it is supposed to be..More to do next week......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:Zapster,These feeding a festoon for offset or gravure printing presses? There aren't many 40,000lb rolls out there.Matt
Reply:Originally Posted by Matt_MaguireZapster,These feeding a festoon for offset or gravure printing presses? There aren't many 40,000lb rolls out there.Matt
Reply:The appleton paper mill near dayton handles rolls that are 80,000lbs, if I remember correctly.  I worked a few months on a construction job there and was amazed at the size of the paper they moved through mill.  I remember seeing one of the rolls marked with the number of yards of paper on the roll.  I don't remember the weight, but there was about 30 miles of paper on the roll.  Enough for me to make a continuous trail from the papermill to my driveway at home... Originally Posted by Matt_MaguireZapster,These feeding a festoon for offset or gravure printing presses? There aren't many 40,000lb rolls out there.Matt
Reply:They take 4 to 5 ton paper rolls and splice them together to make a huge roll then pass the roll thru the machines to do the processes then onto a huge puck-up tube..Then cut them back apart to 4 to 5 tonners again..Paper gets very heavy very fast.....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:Thats great work ZapUA Local 598
Reply:Originally Posted by A_DAB_will_doThe appleton paper mill near dayton handles rolls that are 80,000lbs, if I remember correctly.  I worked a few months on a construction job there and was amazed at the size of the paper they moved through mill.  I remember seeing one of the rolls marked with the number of yards of paper on the roll.  I don't remember the weight, but there was about 30 miles of paper on the roll.  Enough for me to make a continuous trail from the papermill to my driveway at home...
Reply:Originally Posted by zapsterThis is where they go..http://www.vacumet.com/Next time I go there I'll try to get some pics of the paper rolls..You won't believe it!...zap!
Reply:Zapster, very kool as usual. U gotta a lot of skill and talent. ? Without going beyond what you feel comfortable with,  could you share where and how you acquired the skills you use regularly. TIG, machining and detailed rebuilding of numerous precision parts for ex.  Many of the younger fellas who aspire to a career in welding would probably find it interesting and hopefully inspiring  (pay attention Lance)...  Maybe start at " I played Drums in  a keen band and then... thaks, BretLincoln Power MIG 215Lincoln WeldPak 3200HDLincon ProCut 25Lincoln WeldanPower 225 AC/DCIf all else fails... buy more tools
Reply:Originally Posted by PapaLionZapster, very kool as usual. U gotta a lot of skill and talent. ? Without going beyond what you feel comfortable with,  could you share where and how you acquired the skills you use regularly. TIG, machining and detailed rebuilding of numerous precision parts for ex.  Many of the younger fellas who aspire to a career in welding would probably find it interesting and hopefully inspiring  (pay attention Lance)...  Maybe start at " I played Drums in  a keen band and then... thaks, Bret
Reply:I have a question....Post 13, last picture, titled ' anti-vibration tool'...........I'm not a machinist so am not familiar with what you did there and why you did it...I've played around with lathes and mills a little bit and know sometimes you get a chatter or vib going on...How does a crescent wrench solve this issue?...does just the weight hanging off the back twist/torque the tool enough to stop the chatter?....
Reply:Originally Posted by TEKHow does a crescent wrench solve this issue?...does just the weight hanging off the back twist/torque the tool enough to stop the chatter?....A lot of work. You did a super job of it though. Very nice job and write up.   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:Originally Posted by irish fixitA lot of work. You did a super job of it though. Very nice job and write up.   Thanks.
Reply:Originally Posted by zapsterYup..That's all you need to do sometimes..Just one of the many tricks up my sleeve..When thin tube rollers start vibrating well that's a whole different ballgame......zap!
Reply:Originally Posted by Matt_MaguireThere are few things as troublesome as turning long small diameter rod and soft thin wall tubing.Some years after I no longer worked with the above I came across an old time method for fine finish turning difficult things. I learned a different grind profile than the link below shows but the chip is the same. The depth of cut as I grind the tool is .004" at best, but the feedrate can be quite high and still get a good finish. Playing around I was able to work with a long piece of 1 1/2" unsupported black pipe and clean up a pretty nasty rough cut.http://www.machinistblog.com/how-to-...ool/#more-2847If you get a chance to play with this "don't handle the chips" they are so sharp you're cut, and don't know it till you handle something later.MattPS I can remember hanging junk on things, laying bars on tools, solid carbide toolholders and boring bars with sizzlers inside, it was all part of it, sometimes just tough...
Reply:Originally Posted by irish fixitYep that method works a treat on tough jobs if you've got the time to take the small passes.   I've also wrapped things with rubber more than once to try and help dampen the vibrations.
Reply:I have used a wheel weight (the lead kind) to dampen a nasty vibe on my lathe.  I just rest the weight against the tool and work and it helps to eliminate the tool chatter marks and grooves.  I learned that trick on an old brake lathe that was worn out a hundred years ago and needed to be replaced, but the shop owner was too cheap, so we figured all kinds of "strategies" to make that POS do what we needed.  Zap is right about a dieing breed, all the youngsters seem to think they are a "machinist" if they can follow g-code on a cnc machine and have no rejects.  There is way more to the art, and if we dont start teaching this to the next generation it will soon become a "lost" art.  I never made the mad money, but I did manage to eat, have something to drive and raise 2 families along the way.   I have never looked back and regretted the fact that all I ever was was a "hand" on the job, and I looked forward to going to work every day cause I knew it would be something different from yesterday..  I still love this stuff, after 30+ years....I'm spending my Kids inheritance, I dont like him that much anyway!!!!!!Enuff tools to do the job, enough sense to use em.Anybody got a spare set of kidneys?  Trade?
Reply:Originally Posted by zapsterI just use a heavy chain bolted to the back of the carrage and wrap it over the roller in front of the tool..It travels with the carrage so the tool don't get all tangled up with it......zap!
Reply:Originally Posted by RbeckettI have used a wheel weight (the lead kind) to dampen a nasty vibe on my lathe.  I just rest the weight against the tool and work and it helps to eliminate the tool chatter marks and grooves.  I learned that trick on an old brake lathe that was worn out a hundred years ago and needed to be replaced, but the shop owner was too cheap, so we figured all kinds of "strategies" to make that POS do what we needed.  Zap is right about a dieing breed, all the youngsters seem to think they are a "machinist" if they can follow g-code on a cnc machine and have no rejects.  There is way more to the art, and if we dont start teaching this to the next generation it will soon become a "lost" art.  I never made the mad money, but I did manage to eat, have something to drive and raise 2 families along the way.   I have never looked back and regretted the fact that all I ever was was a "hand" on the job, and I looked forward to going to work every day cause I knew it would be something different from yesterday..  I still love this stuff, after 30+ years....
Reply:Originally Posted by irish fixitThat's a interesting idea. I'm sure there's been some real interesting ideas tried to combat chatter. Always something new to learn.