Cracked hydraulic valve

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The last few days I've been chasing down leaks in my bender.  I think I've got most of them cured now and ran into another problem.  Upon reassembly I found one of the work ports cracked on this valve.  A new valve will set me back about $100 which I don't have right now.  So I am tempted to try and fix this thing.The plan is to grind out the crack, braze it back shut,  chase the threads and reinsert the fitting.  Then fillet braze the fitting.Think it will work?  I have my doubts, but the money for a new valve is a few weeks off and I already have everything to attempt a repair.  The valve is guarded and pointed toward the ground. So if it fails I'll only be out some time, some fluid, and some floor dry.What do you think?  The red line is where the crack is. Attached ImagesMy name's not Jim....
Reply:is it cast steel ?I forgot how to change this.
Reply:My concern here is warping the bore for the spool. That's a super precision bore for the spool to work in and any change will cause the spool to bind. You will also need to get the o-rings out of the same bore before doing anything. I'd be tempted to try nickel rod instead of brazing just to keep the chance of warping down.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:I was thinkin if its cast steel open it up with a cut off saw and tig weld it back togetherI forgot how to change this.
Reply:O-rings and spool are already out.  As close of a fit as it is, I'd think the spool would bind if the bore warps.  I'll know that before installing it in the bender.  I was planning on Tig brazing with sil bronze.  I just got done grinding it out.  I think I'll give it a whirl.  It may end up in the scrap bin, but it's headed there anyway if I don't try.  Did I mention I hate working on anything cast?My name's not Jim....
Reply:worse that can happen is u will be waitin a week or two to use your machine check here for a replacement www.surpluscenter.comI forgot how to change this.
Reply:Yeah, burn it. Then stand well clear when you turn it on! How do you clean all the oil out?  City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:If the spool warps you might get away with honing it out before scrapping it, just a thought.I forgot how to change this.
Reply:Originally Posted by LawsonWeldingLLCworse that can happen is u will be waitin a week or two to use your machine check here for a replacement www.surpluscenter.com
Reply:Spool still fit so I went ahead and snugged up the fitting, then brazed it. Done! I think....My name's not Jim....
Reply:Originally Posted by tanglediverHow do you clean all the oil out?
Reply:Originally Posted by BoostinjdmI'd tell ya, but I don't think we need several pages of people saying it isn't safe....
Reply:Maybe Uh Brake clean and a striker? just guessing LOL!!
Reply:Awesome fix not Jim  and your cleaning secret is safe with me. MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Darn nice repair.  Looks solid and well fused so it will probably last longer than the bender now.  Always seems to go that way.  Quick rig to make something go a bit longer and it outlasts the equipment.  Great pics too, not jim.BobI'm spending my Kids inheritance, I dont like him that much anyway!!!!!!Enuff tools to do the job, enough sense to use em.Anybody got a spare set of kidneys?  Trade?
Reply:Great looking repair. Glad it worked for you. I was thinking torch brazing rather than tig thus my warping concern.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:I got a little paranoid and ground half of it back out. I found a few little air pockets near the edge so I filled it back in with a little reinforcement.  Polished the spool (didn't really need to), and reassembled with new o-rings.  Works smoothly, but is a little snug.  I can't tell if it's the new o-rings or what.  I don't think is bad enough to worry about.  If it doesn't leak I'll be good to go.Last pic. Attached ImagesMy name's not Jim....
Reply:New "O" rings will make it feel a little tight.Leo
Reply:Tig brazing is on my list of things to try...  Looks like you got it to lay down nice.Miller 250x & Lincoln V205-TSmith Oxy-Prop torch
Reply:I would have done the same, fix it and plan on ordering a new one when the $$$ is available.Disclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:A good job looks like it will work until a replacement is available I weld a lot of hydraulic parts for heavy equipmentBacked 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:That will hold...What caused it in the beginning?...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:I'm with Zap- its good to go.  Reason it broke? I see it all the time, not a lot of material around bore and the tapered threads when over tightened splits bore. I fix crap like that often.PeterEquipment:2  old paws2  eyes (that don't look so good)1  bad back
Reply:Originally Posted by zapsterThat will hold...What caused it in the beginning?...zap!
Reply:Originally Posted by castweld I fix crap like that often.Peteri think they actually sell those dirt cheap at northern tools ( ferules)  If your hard lines are the same diameter as any home plumbing, home depot / lowes sell many.. and brass is brass....miller syncrowave 250hobart handler 140home made 400 amp engine driven in progress...
Reply:Originally Posted by jdchmieli think they actually sell those dirt cheap at northern tools ( ferules)  If your hard lines are the same diameter as any home plumbing, home depot / lowes sell many.. and brass is brass....
Reply:Finally got my bender put back together and running last night.  The only leak in the whole system is my brazed fitting.  It appears to be seeping out around the threads.  Just enough to get wet, not enough to drip.  So I'm going to say "good enough".  I never did end up getting the right ferrules for the steel lines.  I got creative and added an O-ring to the old ferrules and got lucky.My name's not Jim....
Reply:Really all that and it seeps ...Oh Brother.Miller thunderbolt 250Decastar 135ERecovering tool-o-holic ESAB OAI have been interested or involved in Electrical, Fire Alarm, Auto, Marine, Welding, Electronics ETC to name a just a few. So YES you can own too many tools.