Little Giant power hammer repairs

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Hi everyone!I'm newly registered here, been looking/learning for a while...I have a question about machining filler material added to existing steel, not sure what the composition of the base steel is and I don't know what filler rod to use. I'm assuming MIG will be the best way to apply filler. The parts I am repairing are the Toggle Arms for a 100# LG Power hammer. I have a mill to do the machining. The old holes are crocked and sloppy. I will also be turning new link pins to fit the holes. What I need to do is fill in the old holes and also build up the faces on both sides to fit the yokes then machine them all nice and parallel. Any guidance on procedure will be greatly appreciated. Thank you!
Reply:Can you post pics?? If the parts are for a power hammer, i think that er70 s2, or s6 filler may be too soft for the application. If the original holes got sloppy from the stress of the machine, I feel using the right filler with a stick welder or tig welder may be a better choice; purely because of the necessary filler rod. If the er70 will work, then mig would do the job well, Also, you may have some different filler wire for the mig welder, one that may be better suited to the job. I would hate to see you do hours of work, only ot have it get out of shape in a big hurry.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:Call up Sid, at Little Giant, and ask him.He can tell you the best way to do this.I believe he does it as a repair service, and he also has new toggle arms, but only for one of the three generations of 100lb hammers that were made.He is a good guy, and helpful, and he knows more than anybody else about Little Giants.http://www.littlegianthammer.com/
Reply:Hi-Not sure if was able to transfer photos. This is a 50# I was looking at.... Basicly the same arm set up as these. Attached Images
Reply:If you have a milling machine why not just make new toggle arms from scratch?It's not a "historically correct" repair, but it would be a heck of a lot stronger than a repaired casting. Drilling for grease fittings at the pivot pins would be a nice touch.-Matt------------------------------------------
Reply:The original arms are probably not castings, but forgings. Which are much stronger than a machined part would be.A forging will have grain direction following the curves of the part, rather than having cuts across the grain like a machined part would be.Blacksmiths have been known to forge new parts for other brands, like Bradley or Beaudry, which have NO parts available. Sid stocks replacement parts for the later Little Giant's, but, since some of them date back almost 100 years, and there were at least 3 major series, each slightly different, yours may or may not be available.
Reply:I agree with Ries. They are probably forgings. Keep the original arms, both for originality and strength.I believe you meant to say 'cracked'; if so, ' V ' out the crack and fill it in with new material.Sometimes when the holes are only slightly oversize or egg-shaped, they can be easier bushed, but if badly oversized or out of round, won't be as strong as a rebuilt (welded) end. If they were castings, the best fix would probably to both fix the crack and fill the holes with brazing, then redrill to the correct size. That wouldn't weaken the cast iron by overheating it as welding would.
Reply:Thanks for all the ideas guysMy understanding is that they are forget, not cast. I thought about bushing the pins but have decided against it because of the pounding they are subject to (no pun intended). Also, I need to build up the sides around the pin holesMy quandries are: should I preheat before welding and what type of filler rod should I use for machinability and streingth. I have tig and mig as heat sources as well as OA +++++I do think I will try to put Zerks for lubrication.Anyone have a chunk of 4140 3" X 4" X 12" or 24" annealed? I also need to make some new diesIf I can work this out without asking Sid at Little Giant, I'd prefer it. How many times have you been asked to explain a process that you have spent years proffecting and didn't received anything for it. It's out'a respect for his time.
Reply:I dont know- me, I ask the people that know the most. And Sid is that guy. If he feels like he doesnt want to tell you, and will only do the process for money, well, fine, you havent lost anything- but from what I hear, thats not how he rolls.He loves little giants, and, yes, he is in business, but the way I hear it, he is willing to talk and help as well as sell parts.But since he has talked to a couple hundred other guys who have tried all kinds of fixes, he knows what works and what doesnt, and I think you would be silly not to pick his brain.He makes his money on parts, which plenty of people dont want to make themselves, and on rebuilding and selling whole machines. And he is a heckuva nice guy.Me, I have a self contained air hammer- no linkages, no Little Giant wiggle dance, no possibility of spring parts flying thru the air. (I know a good dozen guys who have homemade spring guards on their LG's- installed after near misses)I know, lots of people love LG's, but my little chinese chambersburg copy hits harder, is quieter, and has far fewer moving parts to break. And hopefully, by the time it needs rebuilding, I will be gone.
Reply:OK Ries, you convinced meI looked for a used  self contained air hammer and couldn't afford it them. I'm just getting back into smithing.  and setting up a my new shopSo many tools to buySo little money
Reply:Oh ya, I'm hoping, if I rebuild it right, I too will be gone before the next rebuildI have replaced the spring, ouch!