Another Hack Job...

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I am convinced you will NEVER see it all in this business...Got another roller to replace the end on..Rubber covered..REALLY heavy...Rubber can be removed for repair purposes...OK now..stay with me.....The way I figured this out took some heavy thinking but I came up with the way whoever tried to save this and it DID NOT WORK!!!By studying the pics maybe you will "See" this also...My take on this..The original journal was 14" long..At about 1" out from the roll face it started to crack from the pressure..SO...Someone took some 6.5" tubing with a 5/8" wall and cut it in 2 pieces..1 was 2" long the other was 1.5" long.They took the 2" piece and welded it over the journal to the head on the inside and outside..Then they took the smaller piece and welded it to the other piece then made a "Head" where the journal stuck out and called it a day.It actually lasted about 6 months but they all fail in the end..Yeah I know it makes no sense at all..So on with the pics..Broken end with cartridge type bearing still installed..Here is the "Half way weld"..Note where there was NO penetration on the OD of the tube..Here is the "Weld" on the inside of the head..Another View..(If you can call it one)..Roller in the lathe..As we continue.....zap!Last edited by zapster; 06-11-2013 at 10:10 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:Here is the inside of the tube on the roller face..Got to lose all of everything left..Roller end done..Parts for a new end..The shaft is done..One more time.....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:OK now we heat the new head.....004 shrink.Installed..Positioner in use..Welds..This is what I will use for the tubing so it "Looks" the same...but in one piece..The fun continues tomorrow so until then...I 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:Must have made quite the racket when it let loose.  Can't wait to see the finished repair tomorrow.
Reply:Boy, that kind looks like what is gonna happen to the BRUINS     when the HAWKS work them over .
Reply:Originally Posted by BD1Boy, that kind looks like what is gonna happen to the BRUINS     when the HAWKS work them over .
Reply:Originally Posted by zapsterIt's not over 'till it's over.Keep that in mind....zap!
Reply:Nice weld zap, can't wait to see the finished repair tomorrow. I enjoy your work.Miller Maxstar 200 SDPiperliner #10 Gold
Reply:I will not pass judgement as I am not immune to doing some bone headed things similar. Although it usually involves parts not available in a timely manner and a lot of hay to chop or some other emergency. You know as you are doing it that it may not last and that you are making things harder to fix later but you have to try.  Some of my most extreme farmer engineering happens at 10pm or later on a friday or saturday night.Millermatic 252millermatic 175miller 300 Thunderboltlincoln ranger 250smith torcheslots of bfh'sIf it dont fit get a bigger hammer
Reply:I often get amazed at man's so much ingenuosity and skill ... You're an artist mister !
Reply:Alright...As we continue...I turned the head I installed yesterday and gave it .005 shrink to the tube..Tube and shaft..Now we heat the tube...Install to the head..Finish weld..May not look too good but it all gets turned off anyway..Next!...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:Now it's back in the lathe for final finish before installing it to the roller..The pilot is .002 bigger than the bore in the roller....If you go back and look at the finished end of the roller you will see a .060 step with a 6.450 ID finish..If all goes well the pilot and the step will do all the shrink fit..Pilot and tube end finished for shrinking..I like to do the radius after facing the head while it's not on the roller yet..MUCH easier that way..Heat face and install pilot and tube end on lip..Lip secure!..I know the pilot is anyway...First weld pass..One more time.....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:Finish weld pass..Finished end..Now it has to go down front to the BIG lathe..Mine is too short by 10"..All set up..Journal finished..See the nice radius?The finish diameter is 1.937+.0001  -.0000I gave it .0001The bearings that go on the end are heated in OIL for expansion to fit the journal and once cooled you need a torch to cut them off if they are installed in the wrong place..BUT that's not my department so with that it's out the door and have a nice day!I get all the fun jobs.......zap! Attached ImagesI 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:Sorry about the finished end pic that showed up at the end..That's the way it goes sometimes....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:After that, the Bruins game and a beer are well deservedDisclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:Originally Posted by TozziWeldingAfter that, the Bruins game and a beer are well deserved
Reply:@ Z - Professional work. Your plan of attack and resultant solution are top-tier.  When launching into the lathe and mill world, gun'a pay you a visit for some "101" machinist training. Will bring brats n beer! Aloha."Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:Thanks zapster I liked that post, very interesting.Magazines have issues, everything else has problems
Reply:Originally Posted by zapsterYou got that straight my friend......zap!
Reply:That turned out awesome. Boy, you really no your $hit. Nice job.
Reply:good repair.. How do you do the +.0001" diameter? Do you have a tool post grinder or polish it in? Or do you feel comfortable cutting to thatHTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.
Reply:I've read a bunch of your threads where you are fixing these things zap, and I'm embarrassed to say I haven't been able to tell what the hell they are, what they do, and why people break them!?I googled journals and rollers and got more confused. So I gotta ask what the heck is it, or what do I google to read about the dang things?
Reply:Originally Posted by fordmangood repair.. How do you do the +.0001" diameter? Do you have a tool post grinder or polish it in? Or do you feel comfortable cutting to that
Reply:Originally Posted by BrownfauxI've read a bunch of your threads where you are fixing these things zap, and I'm embarrassed to say I haven't been able to tell what the hell they are, what they do, and why people break them!?I googled journals and rollers and got more confused. So I gotta ask what the heck is it, or what do I google to read about the dang things?
Reply:Interesting stuff Zap. Thanks for posting it up.Originally Posted by BrownfauxI've read a bunch of your threads where you are fixing these things zap, and I'm embarrassed to say I haven't been able to tell what the hell they are, what they do, and why people break them!?
Reply:Cool. Yeah i love the how it's made shows, and now I get it. Pretty neat how you fix that stuff. I'm constantly finding things that we rely on welding for and finding a new appreciation for the skill it takes.
Reply:I'm amazed at the level of precision you can get on these things man. I read so much about lathes and how ways that are a bit worn can add taper to a cut and can't hold tight tolerances, etc, and I'm curious, how "perfect" are the ways on your old monster lathes?miller 330a bp TIGmiller dynasty 200DX TIGmillermatic 185 MIGthermal dynamics cutmaster 101 plasma cuttersnap-on YA5550 plasma cutterhypertherm powermax 30 plasma cutterbaileigh CS225 cold sawetc....
Reply:Originally Posted by turbocad6I'm amazed at the level of precision you can get on these things man. I read so much about lathes and how ways that are a bit worn can add taper to a cut and can't hold tight tolerances, etc, and I'm curious, how "perfect" are the ways on your old monster lathes?
Reply:ok but what happens if you get the same reading at the head and at the tail, but the reading changes slightly in the center? I think this is what happens with ways that are pretty worn... where the ways are worn the tool will kind of drop down and out slightly, causing less cut where it's worn the most. I can see how offsetting the tail to exactly match the cut at the head can make both ends cut to exactly the same dia. but can there still be issues throughout the whole length of the cut like in the center part? I ask because my ways are pretty worn and it bothers me enough that I sometimes consider replacing the lathe because I feel like it's just no good, not that I have ever personally even seen the results of a problem myself yet first hand, but from everything I've read I feel like my worn ways are just no good at all which is why I ask about yours... maybe I'm overthinking the worn ways issue I guess, and I think it would only be an issue on longer length cuts too I guess...miller 330a bp TIGmiller dynasty 200DX TIGmillermatic 185 MIGthermal dynamics cutmaster 101 plasma cuttersnap-on YA5550 plasma cutterhypertherm powermax 30 plasma cutterbaileigh CS225 cold sawetc....
Reply:There are leveling jacks built into the bed base on the 42 footer..Forgot to mention that...Very trickey operation to level a lathe but it can be done.....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.