Repair of 12.5 Ton Log Splitter

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In 2010 I repaired the slider bracket that attaches to the ram on my friend John’s 12.5-ton log splitter, which was 1-1/2 years old at the time. In addition to full penetration TIG welds, I also increased the length of the diagonal brace. I believe that the root cause of the failure was a defective cold lap weld. Do you agree? The repaired bracket has held up 11 years and is still going strong after splitting thousands of logs. 1. Damaged Bracket on Log Splitter

2. Full View of Broken Log Splitter

3. Cold lap on right side

4. Rusted cold lap

5. Outside Weld

Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE  31 MP & Lincoln 210 MP
Reply:6. Side weld

7. Bracket All Done

8. The bracket today - 11 years later

9. Full view today - 11 years later

-DonSmith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE  31 MP & Lincoln 210 MP
Reply:Good job!! The crappy factory welds were a big contributing factor. Maybe a little grease on the under side might have prevented this.Last edited by mla2ofus; 2 Days Ago at 09:51 PM.Ol' Stonebreaker  "Experience is the name everyone gives to their mistakes"Hobart G-213 portableMiller 175 migMiller thunderbolt ac/dc stick Victor O/A setupMakita chop saw
Reply:Nice repair. Certainly looks like cold lap to me.Miller Multimatic 255
Reply:Great work.  Your Repair/upgrade is much better than the original.100% Agree about the causes, cold lap first and relatively bad design second (though it may have been adequate with a good weld).  Looks like major cold start/lap that the crack started at, and ripped through the weld bead where there was penetration.  The cold lap was not helped by the difference in material thickness, and the likely orientation of the weld when made (thicker material on the bottom, thermal dynamics working against you).Having the vertical brackets run the full width of the horizontal piece (like your repair) moves the weld stress from purely shear (relatively weak) more to tensile (best for welds), in addition to helping box in the assembly (more rigid).  Good lesson in simple, small changes that can make a big difference.Last edited by SlowBlues; 2 Days Ago at 10:02 PM.
Reply:Kind of a tender machine in the first place. Mine, homemade in 1981 has about a foot long box that rides the flat plate. It's a good deal heavier built than yours.No easy way to extend the length of the portion that slides, so to avoid it binding like a sticky drawer, lubricant is essential. I use bar & chain oil on mine.Having suffered a life threatening injury from a block of wood that jumped out of a splitter, I have a series of nuts welded around the perimeter of the push face.An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.
Reply:I had a similar cold lap joint with a loader bracket on a tractor. Cant locate then picture, but the bracket peeled off due to lack of factory fusion. If i find the pic will post itGeezerPower Mig 255C185 TIGBlue 175 MIGRanger 8 Kohler 20HP1974 5K Lincoln/Wisconsin Powered (Cherry)Victor/Harris O/AK 487 Spool Gun
Reply:Funny thing about a fillet weld.It's never truly in tension, or shear.  It's the nature of the beast.Transverse loading is the strongest orientation.  Which the log splitter ain't......no matter how much bracing you add.As a matter of fact, the splitter thing is in shear 100% if you discount the hinge on the leading edge weld.  It was the shear that caused it to fail, and it still exists.To get around this, as has been done, build the joint overstrength.  It works, and is totally acceptable.  But don't talk about shear/tension unless you're fully versed on the situation.
Reply:

Originally Posted by farmersammm

Funny thing about a fillet weld.It's never truly in tension, or shear.  It's the nature of the beast.Transverse loading is the strongest orientation.  Which the log splitter ain't......no matter how much bracing you add.As a matter of fact, the splitter thing is in shear 100% if you discount the hinge on the leading edge weld.  It was the shear that caused it to fail, and it still exists.To get around this, as has been done, build the joint overstrength.  It works, and is totally acceptable.  But don't talk about shear/tension unless you're fully versed on the situation.
Reply:

Originally Posted by Willie B

I ain't as smart as you. I look at successful splitters, look for the differences of good vs. broken. I'd prefer to see a longer interface between beam & slide to avoid sticky drawer binding. I can't say whether galling is evident. Unless you only split consistently sized wood cut perfectly square, there'll be some cockeyed strain.
Reply:Log Splitter DonetheKieth Fenner wayLookit the bearing plate on that thing..............it's long.  It's the way stuff oughta be built.
Reply:And, if ya look close..................the cylinder rod points down as it moves.  Places the stress against the beam, not against the bearing plate