Bulldozer wishbone repair

admin

Hello, My friends JD 550 has a previous repair on the left side of the wishbone that the blade mounts to. It is plated on all 4 sides with 1/2 in plate where it curves around at the front towards the center blade pivot.  When I had it on my property last week clearing stumps  I noticed the right side was cracked in the same area. It was not a new crack- I didnt do it   I told him I would fix it since hes been a friend for ten yrs and he is giving me a great deal on using his dozer.   Got it here to the city house and found its cracked top and bottom on that inside curve and partway across the top and bottom of the arm.  Did a bunch of grinding today and stop drilled . Friday will make patterns and cut out 1/2 in thick doublers for it with plasma cutter. Top and bottom not a problem but bending .500 plates for the curved sides wont be easy.  May have to make some kind of steel buck to bend that inside piece over. I guess the outside one I could weld one end of it on and then heat it up and get some big C-clamps to bend the other end around ??  Figure on using DC rev arc for the welding, hows that sound?   Dave Attached ImagesLast edited by davo727; 05-05-2011 at 11:55 PM.Reason: fixd my error on arc typeMiller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Some grinding on upper side Attached ImagesMiller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Nice dozer and pics dave, I'd weld that with 7018 rod (electrode positive)."The reason we are here is that we are not all there"SA 200Idealarc TM 300 300MM 200MM 25130a SpoolgunPrecision Tig 375Invertec V350 ProSC-32 CS 12 Wire FeederOxweld/Purox O/AArcAirHypertherm Powermax 85LN25
Reply:Gotcha, Thanks-  DC reverse- is what I want to do. I goofed it up in my head and typed in EN in error thie first time,  edited it now Last edited by davo727; 05-05-2011 at 11:55 PM.Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Would it be good to lay in a first pass with 6011 DC rev?   Or all with 7018 ?Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:My understanding is if you've gouged all the way thru and have an open root, you'll want to run a root pass with 6010/11 or use a backing strip (I'm assuming back grinding is out from the picts). If not there's a strong chance you'll have porosity issues with your 7018 root. On joints that don't have an open root you can run 7018 all the way..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:What DSW said.  On an open root you can use 6010/6011.  I would then dress it up with the grinder again.  Make sure you clean all the slag out.  The next pass you want to run a hot pass with the 7018 and then fill and cap with 7018.  I would rent a magnaflux unit before I start welding and make sure I had all my cracks  found.  you can often find a enginebuilder to rent one from or pay him to do it.
Reply:You need to gouge or grind the root open and place a backing bar inside.  Then you put a good bevel on the plates with a feathered edge and run 7018 all the way.AWS Certified Welding Inspector,certified welder (unlimited 3G/4G)NDT and Coatinge inspectionShieldarc 250Presion TIG 225Alpha 200xChop sawDrills / grindersband sawoxy/acetylene hand toolsEtc....
Reply:For the 1/2 plate you could just tack one end and beat it to shape, welding as you go it might take a little doing and will be loud but it should work, might not even need heat. I have bent 3/8 this way quite a few times so I would imagine it would work just fine on 1/2 you might just need a bigger hammer.
Reply:whats the repair on the other side look like?
Reply:Cut the top and bottom .500 doublers out with the longevity 60. Attached ImagesMiller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Thanks for the advice, will do the best I can with it but no access for backing strip so I guess it will be6011 to close it up and then 7018 to fill the V . Then grind smooth and weld the doublers on.Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:read up on making a hot pass.  that is the key to making the 6010/6011 root work and not needing a backing plate.  the hot pass will dilute and/or release any hydrogen the 6010/6011 picked up.as far as your doublers are concerned, I would make the ends shaped like diamonds.  You don't want to carry a weld perpendicular the tube or create an undue stress riser.
Reply:There is no accses so you need to open it up with a gouger or grinder.  If you get a 1/2in opening you can wiggle a backing bar into place.  6010 rods are great for many things but not heavy equipment.  Also opeing the root up will give you greater accses and make it easy for you to clean all you slag out, you will also be able to use a larger rod for higher heat input which will also help with underbead cracks in you base metal and make for faster welding.    AWS Certified Welding Inspector,certified welder (unlimited 3G/4G)NDT and Coatinge inspectionShieldarc 250Presion TIG 225Alpha 200xChop sawDrills / grindersband sawoxy/acetylene hand toolsEtc....
Reply:Josh, There are multiple ways to skin a cat. Shaping a backing bar to the inside corner radius of that tube along with the curve is just crazy.  6010/6011 is used on many applications.  the only thing I would highly suggest is magna fluxing the area.
Reply:davo727,Please indulge us with some pictures of your gooseneck and tow vehicle.Regards
Reply:[QUOTE=Scott Young;507072]Josh, There are multiple ways to skin a cat. Shaping a backing bar to the inside corner radius of that tube along with the curve is just crazy.  6010/6011 is used on many applications.  the only thing I would highly suggest is magna fluxing the area.[I know 6010 are used everyday on many applications(i have used them quite a bit), but every rod has there own applications and strenghs.  Its never crazy to do the job the correct way, but if you are set on a open root.  Why not run 7016 which are rods designed for open roots, low-hy, and also higher tensile strengh. I know we all have are own ways of doing things and thats ok.  Using a mag particale unit or dye pen would be great to check for surface cracks.AWS Certified Welding Inspector,certified welder (unlimited 3G/4G)NDT and Coatinge inspectionShieldarc 250Presion TIG 225Alpha 200xChop sawDrills / grindersband sawoxy/acetylene hand toolsEtc....
Reply:Thanks Josh for the info- I will try and get some 7016 for the next project. Already welded the roots closed yesterday with 6011 and peened the crap out of it with needle scaler   Capped part of it with 7018 and it looked beautiful.I finished preparing the 4 doubler plates last nt, but right now im in the middle of a double shift at my real job at the airport.  The free bulldozer welding is just for fun.  Will be four days before I can get back on the dozer job.  The 2002 F350, triple 12K axle trailer and JD 550G all belong to a friend of mine.Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Always nice to have a project like that and a full time job matter a fact.  Good luck with it and let us see some pics when you get a chance.AWS Certified Welding Inspector,certified welder (unlimited 3G/4G)NDT and Coatinge inspectionShieldarc 250Presion TIG 225Alpha 200xChop sawDrills / grindersband sawoxy/acetylene hand toolsEtc....
Reply:Bottom plate is mostly on, the inboard side needs several more passes. The outboard side is not too pretty- will try to be more steady on the rest   Disclaimer: Im fully aware of the fact that im not a professional welder    Attached ImagesLast edited by davo727; 05-14-2011 at 01:48 AM.Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Sorry about the blurry pic but this is the inside upper radius welded up where the crack was. Attached ImagesMiller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Heres where the crossways crack was on the upper beam, welded up and ground flat. Attached ImagesMiller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Upper plate tacked on. At a stopping point cause its dark and I have to go back to work in the morning. My friend Bill is taking the dozer and getting a root rake installed on the front by a shop in cleveland tx and in 4 days will bring it back here and I will continue on the welding. Attached ImagesMiller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Davo - repair is coming along pretty well , don't forget to wrap the shaft on your Hyd. cylinder - one buckshot will ruin the packing. Good job.
Reply:Looking good Dave.  I commend you on taking the initiative to fix this in return for the use of the machine. 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!Thanks for the comments. Swamp rat: Yes thanks I will make sure the cyl is covered, I did have the front pin of that actuator out and the cylinder tied up about 6 inches higher when I was working. In the pic it is back in the normal installed spot, your comment has made me think of an idea- I will get a piece of tin stovepipe sheetmetal and wrap it around the cyl before I do the finish welding. Thanks Duane b , this is a great learning opportunity and I am getting good satisfaction from doing it but it is taking a whole lot more hours than I thought it was going to, but I take a lot of breaks I am very curious what a shop or mobile welding truck repair guy would charge to do this job??  This is for my friend so Im not charging , just wondering.Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Worked on it some more yesterday and today. Made up a little bitty clamp to bend the side plate around. The last pic is on the 3rd bite with the clamp- the end of the doubler is about 3/8 inch from the beam. darn it!   After I get the doubler welded in more securely then I can release the clamp and get one more bite on it to get the front tip of the doubler plate down flush against the beam. The clamp bolts are  1.125 inch B-7 threaded rod, and 4 inch channel.Ref the first pic:You cant see it but I  welded a little 1/4 in tab to the doubler so that the right inside edge of the outboard clamp catches on and that keeps the clamp from sliding over to the left when tightening the bolts. Attached ImagesLast edited by davo727; 05-28-2011 at 11:21 PM.Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:In the last pic the clamp is actually welded to the doubler so it cant slip off.The nuts on the clamp are 1 and 13/16 inchLast edited by davo727; 05-28-2011 at 10:08 PM.Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Fascinating repair - Great post!Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:davo727  -  The generally vertical crack in photo # 2, 3, and 4 is the focus of the repair.    This crack is the hinge of the failure, and all of your doublers should be designed distribute the working load well pasted this failure-point to a greater surface area.  Don't torture yourself; make a hi-definition pattern out of hi-density cardboard and give it to shop that has the vertical breaks to effortless form them in seconds.   And full credit to all that mentioned that the root was'nt deep enough.    Opus
Reply:Once you get the rest of the fish plate welded and take the clamp off you should be able to hammer the rest of it flat with a 3lb or so hammer.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:Thanks Wayne. I will do that.  Originally Posted by irish fixitOnce you get the rest of the fish plate welded and take the clamp off you should be able to hammer the rest of it flat with a 3lb or so hammer.
Reply:Originally Posted by davo727Thanks Wayne. I will do that.
Reply:Outboard side plate welded in except for front tip. Tried the sledgehammer deal and it just bounced off the tip of the plate, with no movement on the plate. I stuck a little piece of square stock inside the clamp and then cranked it down and mashed the plate down flat. Will leave it clamped overnight and weld it in tomorrow. Something funny if you look at the top plate- there are two different looking welds on it. That is because I had tacked the plate on and my friend took the dozer to have a new root rake mounted on the front and the rake shop went ahead and welded down the top plate.There was a section of the weld that was bubbled up, I think there was some hyd oil on it and they did not clean it before they welded. I ground down that section and rewelded it. The weld they did is very smooth and looks like it was run very hot. Attached ImagesLast edited by davo727; 06-01-2011 at 10:57 PM.Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Its going to be hard to get at that front tip with the clamp in the way, hopefully I can get some of it tacked down with 6011 to hold it good enough and pull the clamp and final weld.Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Just in case anyone is interested- the 1.125 inch  B-7 grade threaded rod and the nuts were purchased from mcmaster carr online.Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Thanks Originally Posted by Rick VFascinating repair - Great post!
Reply:I welded the front tip of the outside plate. Came to the conclusion that the inboard plate is not going to get bent by me. I made a pattern of the shape it needs to be and gave it to the owner. He says he knows a guy that will bend it for him. He is going to take the dozer for now and will bring it back later on after he gets that plate formed and then I will weld it in. Attached ImagesMiller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma
Reply:Looks good to me. That inner plate would be a bugger without a good press to at least start it with.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:Thanks  Wayne,   I learned a lot. Its not pretty but I think its gonna stay together just fine. Got a lot of Arc practice ( yes I  need more).Last edited by davo727; 06-04-2011 at 01:07 AM.Miller Synchro250 bought new 1997Millermatic200Miller Bluestar 2E . AC/DC 16hpBluestar 2E , DC Miller Thunderbolt225 AC/DC ArcLongevity 60 plasma