Little line boring job

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The top 4 holes were not that bad, pretty straight forward, weld them up, and cut them to size.  The bottom holes were all 1 to 1.5" out.  The play was so excessive that the cylinders had pushed the superstructure back nearly 2 inches.  4 days of solid welding before I could even begin machining.  These bores are right at 10 inches diameter and 7 inches deep.  Unfortunately I did not get any pics of the completed job. Attached Images6 Miller Big Blue 600 Air Paks2 Miller 400D6 Lincoln LN-25's4 Miller Xtreme 12VS2 Miller Dimension 812 4 Climax BW-3000Z bore welders Hypertherm 65 and 85Bug-O Track BugPair of Welpers
Reply:This one is pretty straigh forward and simple. Attached Images6 Miller Big Blue 600 Air Paks2 Miller 400D6 Lincoln LN-25's4 Miller Xtreme 12VS2 Miller Dimension 812 4 Climax BW-3000Z bore welders Hypertherm 65 and 85Bug-O Track BugPair of Welpers
Reply:Originally Posted by ExpatWelderThe top 4 holes were not that bad, pretty straight forward, weld them up, and cut them to size.  The bottom holes were all 1 to 1.5" out.  The play was so excessive that the cylinders had pushed the superstructure back nearly 2 inches.  (snip)
Reply:Matt, We currently do not use AD hoods--(I just ordered 20 Speedglass 9100XX hoods which have not showed up yet)--We also do not use any sort of cooling vests---these guys are tough as nails and will work all day log in these conditions!  Right now we are in the middle of a Muslim thing called Ramadon---(I don't know how it's spelled), anyway, my Muslim welders will NOT eat or drink anything while the sun is out, so I try to keep them in the shade during the day.  This Ramadon thing lasts for about a month.On this same job I welded all the top bores myself one night using one of my Bortech machines and was a flash burned mess for a couple of days---you guys that have done any night welding, especially with a bore welder, will know what I'm talking about.  With the bottom holes beng so wallered out, it was faster to gang bang them with people rather that use the Boretech.  I put 40 lbs of .035 70-S6 in the top holes and we put about 180 lbs of 7018 in the bottom ones.6 Miller Big Blue 600 Air Paks2 Miller 400D6 Lincoln LN-25's4 Miller Xtreme 12VS2 Miller Dimension 812 4 Climax BW-3000Z bore welders Hypertherm 65 and 85Bug-O Track BugPair of Welpers
Reply:what is this on? im assuming mining equipment?
Reply:You 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 ExpatWelderMatt, We currently do not use AD hoods--(I just ordered 20 Speedglass 9100XX hoods which have not showed up yet)-\
Reply:Originally Posted by zapsterYou get all the fun jobs......zap!
Reply:Originally Posted by rusty ripplewhat is this on? im assuming mining equipment?
Reply:Nice piece of work.  Sounds like a real trial by fire to spend all that time just traveling to the job site...A quick question for you.  Since you mentioned using 0.035" S-6, you must have had a wire feeder and shielding gas available.  Did you consider using a gas shielded fluxcore wire, instead of all that 7018?Was it a case of using what was on hand?  Or was there another reason for using stick, when you had such large weldments to make?Deposition rates for the gas shielded fluxcore would blow away E7018 under most circumstances....Knowing only what you've told about the job, I figure even waiting a few days for wire to be shipped to the job site, you'd come out ahead using fluxcore over stick.... Originally Posted by ExpatWelder...I put 40 lbs of .035 70-S6 in the top holes and we put about 180 lbs of 7018 in the bottom ones.
Reply:Originally Posted by A_DAB_will_doNice piece of work.  Sounds like a real trial by fire to spend all that time just traveling to the job site...A quick question for you.  Since you mentioned using 0.035" S-6, you must have had a wire feeder and shielding gas available.  Did you consider using a gas shielded fluxcore wire, instead of all that 7018?Was it a case of using what was on hand?  Or was there another reason for using stick, when you had such large weldments to make?Deposition rates for the gas shielded fluxcore would blow away E7018 under most circumstances....Knowing only what you've told about the job, I figure even waiting a few days for wire to be shipped to the job site, you'd come out ahead using fluxcore over stick....
Reply:' ... the bore was a little bit worn.  It was 1 to 1.5 inches out.  '  Slight understatement award for -that- one.          The best laid schemes ... Gang oft agley ...
Reply:Originally Posted by ExpatWelder  These kind of jobs prove a theory I came up with years ago.   "The 7 P's"    Proper Prior Planning Prevents Piss Poor Performance.---In all honesty though, I really love this stuff, always an adventure and "if it was easy, then everyone would be doing it"
Reply:Originally Posted by Matt_MaguireI got some different ones "Why would you think bad planning on your part should constitute an automatic emergency on my part"?And second "There will be a larger transfer of funds from your bank account to mine"!Sometimes it's "Oh, it was only five bucks to do the fix, the rest is for knowing how"!As for the "if it was easy" part, that only happens when someone else is doing it, that's true for most everythingMatt
Reply:So what schools or institutions offer training for line boring?  I'm currently weighing my options now that I have finished a welding school and would like to look into this side of welding as well as the underwater welding that I'm interested in.
Reply:Thanks Expat, that all makes perfect sense.  I do appreciate the situation you're in.  I spent a week in India last year, where wire welding of any kind is still a rare occurrence.  It's good to hear that your time overseas has been (relatively speaking) a good experience. "Give a man a fish, feed him for a day.  Teach a man to fish, and feed him for a lifetime."Hope your return trip home is soon...-Dave Originally Posted by ExpatWelderDab,  I do have quite a supply of ESAB 7100 Ultra available, but I do not have welding personnel that I feel I can turn loose with it.  Another reason for the 7018 is that these are laninated bores that had the bush wore through for a LONG time so ALL that grease got shoved between the laminated plates and no matter how much heating I tried, I just couldn't slow it down---LH70 is way more machineable/predictable in a situation like that than hard wire, and when using stick, I like to weld perpendicular to the bore, so you don't have a trail of grease following you, it's just in a small place.  The bore welding that I personnaly did on this job, and do, is all with either hard wire or dual shield.  We also use a lot of NR-232 innershield wire, but again, I only have a select few people at this point that I can turn loose with it.  Ya gotta realize that this is a VERY 3rd world location and up till a few months ago most of these guys had never even seen a wire feeder before.  But you should see some of these guys running 5mm 7018!!!  VERY competent.  My job is essentially to work myself out of a job by developing these guys, and I feel pretty confident that we are making great progress, they really want to learn, and I'm just lovin the opportunity to make a difference in someone's life and teach them things that they can use for the rest of their lives.
Reply:Originally Posted by Big65moparSo what schools or institutions offer training for line boring?  I'm currently weighing my options now that I have finished a welding school and would like to look into this side of welding as well as the underwater welding that I'm interested in.
Reply:Originally Posted by Big65moparSo what schools or institutions offer training for line boring?  I'm currently weighing my options now that I have finished a welding school and would like to look into this side of welding as well as the underwater welding that I'm interested in.
Reply:Got another boom anchor job to do, almost identical to the last one that's in the pics above except it's just the top holes, not top and bottom.  The customer wants it started on the 20th but I will be home then, so I figured this would be a good time to see what my boys can do without Dad around.  I will have the lads take lots of pics and will post them once I get back.  They said we could have 72 hours but I think we can do it in 30.  It's 4 holes that are 10 inch diameter by 8 inches deep.  One hole is wallered out to about 14 inches and will take quite a bit of welding, the others are pretty straight forward, 2 passes of hardwire, 1 rough cut, 1 final cut, bingo bango.6 Miller Big Blue 600 Air Paks2 Miller 400D6 Lincoln LN-25's4 Miller Xtreme 12VS2 Miller Dimension 812 4 Climax BW-3000Z bore welders Hypertherm 65 and 85Bug-O Track BugPair of Welpers
Reply:Nice work.I also would like to learn to do that stuff great work.
Reply:That's something i always wanted to learnBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:Incredible work! With the holes so worn, how do you get the boring bar set to the original hole centerline? I would love to see this operation in person......never seen anything like that in my little town. Thanks for sharing
Reply:Originally Posted by monkersIncredible work! With the holes so worn, how do you get the boring bar set to the original hole centerline? I would love to see this operation in person......never seen anything like that in my little town. Thanks for sharing
Reply:Thats some good looking work expat. I am just getting another 64 yd done and an 54 amsco rock bucket to get into next week. Its funny how they run them to pieces but want them new in a few weeks. Your work is top notch sir. We get lots of stuff done by hacks that really adds time to re repair a previous fix. look forward to more pics.
Reply:Seems to me that guys proficient with 7018 could pick up wire feed welding pretty quick.Just sayin'...Im just curious... whats a BIG line boring job for you? just sayin....
Reply:EXpatwelder when you center your bar do you center it off of a part of the bore you left not built up or do you set locate bar before welding. I was told to not weld up one end and center off of it.I worked in a shop that repaired quarry stuff. All of are bars and drive were built by us.The hard part was measuring bores with bar in the way. I made some stuff to do it . Most of the shops I have worked in have a high turnover of workers so if you stayed very long you were left thier to figure it out. It would have been great to have a factore made bar or some one to ask how its done. The bigest bores I did you could stand in and build up.I dont rember but around 4 feet.
Reply:Originally Posted by daddySeems to me that guys proficient with 7018 could pick up wire feed welding pretty quick.Just sayin'...
Reply:Originally Posted by Old DougEXpatwelder when you center your bar do you center it off of a part of the bore you left not built up or do you set locate bar before welding. I was told to not weld up one end and center off of it.I worked in a shop that repaired quarry stuff. All of are bars and drive were built by us.The hard part was measuring bores with bar in the way. I made some stuff to do it . Most of the shops I have worked in have a high turnover of workers so if you stayed very long you were left thier to figure it out. It would have been great to have a factore made bar or some one to ask how its done. The bigest bores I did you could stand in and build up.I dont rember but around 4 feet.
Reply:Guy in the middle drew the short straw?
Reply:Originally Posted by ExpatWelderMost bores we do are in line with 2 or 3 other ones so we can dial in pretty close off those.  If it's just one hole, I can usually find 3 points in the bore to center off of. I have a couple of really neat bore measuring calipers made by a buddy of mine--Jim Miller, MT Cutters--that let you measure the bore with the bar in the way, they're real slick--Climax sells them too but Jim makes them for Climax
Reply:Originally Posted by ExpatWelderThe top 4 holes were not that bad, pretty straight forward, weld them up, and cut them to size.  The bottom holes were all 1 to 1.5" out.  The play was so excessive that the cylinders had pushed the superstructure back nearly 2 inches.  4 days of solid welding before I could even begin machining.  These bores are right at 10 inches diameter and 7 inches deep.  Unfortunately I did not get any pics of the completed job.
Reply:Originally Posted by thartman141Looks like u had your hands full with this one! got a question for ya, maybe you can help me. I spent 20 years in a rock quarry doing maintenance just like this. Ive thought lately about starting a line boring service in NC, VA area. wonder if you could give your thughts about how much business is actually out there and if you would do it again?Thanks much!thartman141
Reply:Just wanted to give an update on how this last job went.  The Machine was supposed to go down on the 24th of Dec and be down for 6 days--144hrs--.  I flew home on the 19th and was supposed to be back on site on the 2nd.  On the 23rd one of our other machines suffered a catastrophic boom nose cone casting failure, pics and story to come later.  This machine needed to be addressed first, which it was and they got it up on the 25th.  We took the other one down on the 26th.  I had hired a contract field machinist to help my boys out and figured between the 3 of them they could get the welding and maching done in 72 hours, he never showed up.  My 2 boys worked a total of 58 hours in 72 and did an OUTSTANDING job.6 Miller Big Blue 600 Air Paks2 Miller 400D6 Lincoln LN-25's4 Miller Xtreme 12VS2 Miller Dimension 812 4 Climax BW-3000Z bore welders Hypertherm 65 and 85Bug-O Track BugPair of Welpers
Reply:Nice when people step up especially when someone else craps on your plans. Keep us posted big projectsMillermatic 252millermatic 175miller 300 Thunderboltlincoln ranger 250smith torcheslots of bfh'sIf it dont fit get a bigger hammer
Reply:ExpatWelder-Thanks for keeping this thread going, I have had several questions answered just reading it.  Thanks again and I always enjoy reading your posts and your work is outstanding.Walt
Reply:I'll second the motion to keep the project details coming....I like reading about all these "little" jobs that you come up with!Andrew
Reply:It's an old thread, but do you have any new projects or photos, Expat?