CAT IT-28 manifold repair

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Repaired a manifold for a 1992 CAT IT-28 yesterday. The exhaust manifold was heavily pitted and eroded due to leaking for a long time. It was brazed up and then roughed out on the cnc mill. I then bored to to the finish size. I figured some of you guys would be interested to see the fixturing. Not seen very well in the photos is an additional machinist jack on the back side. This was an easy fix. Enjoy.
Reply:More work.  What prompted this tear down was a massive water leak between the head and the water pump. It turns out this machine has a seal that expands in the gap using a hose clamp. CAT said it could only be replaced by pulling the head. The replacement part from CAT has a thermal plastic ring that melts if the engine gets overheated. The mechanic asked me to stop by and offer a solution. I wish I'd taken a photo of it. I never would have guessed it would have melted so bad. The rubber looked perfect. He said that the CAT mechanic said some of these seals have a metal ring rather than plastic but that CAT only offered the plastic version. So I made quick drawing and whipped a duplicate out of aluminum. To machine the second operation I use a light interference fit on a turned mandrel. After I machined the back side I had to bore out the mandrel to remove the ring. The mechanic was beyond happy. I hope it works.Last edited by forhire; 02-17-2015 at 05:21 PM.
Reply:Great saves there. It's nice when you can make a part better than the manufacturer.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:Very nice work! ditto irish, always satisfying to improve on oem.www.facebook.com/gstreetworksLincoln Power Mig 210 Miller Maxstar 150Lincoln Idealarc 250/250 G Street Works LLC
Reply:Really nice job on the repair!  The setup probably took way longer than the actual machining!  Happy customer I'm sure!
Reply:That looks like it was fun getting that manifold fixtured up on the mill! Haven't been on the board for long but I always look forward to your projects, always something interesting and excellent work.
Reply:Very nice work Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Great work. Nice save for sure.
Reply:When I see threads like this one, where parts are machined from scratch, it's like magic to me.  I have no idea how you go about doing some of the stuff that you do, but I enjoy reading your explanation and seeing the photos.  Very cool, thanks for taking the time to share.Lincoln Precision TIG 185.Flex-Loc 150 torch.Super-Flex hose.Lincoln MIG 180.Victor Oxy/Act torch set.DeWalt Bandsaw with SWAG stand
Reply:I would expect nothing less from you...Good save!...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 job, nice save.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:nice work fh. there's got to be other machine owners having the same problem. this could turn into something very profitable.i.u.o.e. # 15queens, ny and sunny fla
Reply:Originally Posted by irish fixitGreat saves there. It's nice when you can make a part better than the manufacturer.
Reply:Very good job on the repair. What kinda brazing rod did you use?
Reply:Originally Posted by That Guy ThereVery good job on the repair. What kinda brazing rod did you use?
Reply:The owner dropped the old seal by this afternoon. Crazy how bad it melted. The machine is back together and running well.
Reply:Originally Posted by forhireI suspect I could sell a few if I could figure out what to call it and advertise correctly. I'm kinda clueless on the details. The mechanic said I'd have a market. CAT sold 3 million of these IT-28 machines. Not sure how many others share the same engine. Maybe the mechanic can give me some more details.
Reply:You're such a stud Randy.  You make even the toughest of jobs look easy Expert Garage Hack....https://www.facebook.com/steven.webber.948
Reply:Originally Posted by Brink, M.E.I think that's for a CAT 3116 engine.  Used in everything from trucks/buses to machinery to stationary equipment.
Reply:nice job.great work.Impressed.
Reply:Originally Posted by admsweldingnice job.great work.Impressed.
Reply:Nice to see that kind of work, and your not even exhausted.
Reply:What temp does the exhaust get up to?I have seen glowing red manifolds. Just curious how the braze holds up. I truly have no idea. Not knocking it at all.Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:Originally Posted by partsmanNice to see that kind of work, and your not even exhausted.
Reply:I always thought brazing was only good up to about 800 deg's?Originally Posted by Welder DaveI always thought brazing was only good up to about 800 deg's?
Reply:Check your pms. Id love to pay you!  Thanks again.
Reply:Wow great job. Looks cleanESAB Powercut 1600/ Hypertherm 30XP + 45XP/ Lincoln Powermig 255/ Jet Band SawCheck out my plasma cutter reviews also!Current Project: 175 Gallon Reverse Flow BBQ Smoker!
Reply:Originally Posted by brendonvCheck your pms. Id love to pay you!  Thanks again.