Just When You Thought You Have Seen It All..

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Big roller to repair the journals on..Seems that whoever owns it has a bunch of complete IDIOTS running the "Show"Only have 2 pics today..I'll take more tomorrow..This is rubber covered and weighs in at 4450 LBS..Below is the short end..If you look close the rubber is coming off the roller on the short end..It's overlapping the seal area..Long end..If you look close the rubber is going away from this end..Now here is the cause..The short end bearing size is 119 MM (3.682?)..... I forget now....However the long end bearing size is 3.937...This has been run "Downhill" for awhile..This is also a pressure roller that's under 3 tons of pressure..And ya wonder why the rubber is sliding off to one side..I don't know where they find these guys but what the heck..It will keep me busy for quite awhile..To be continued.....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:it's only an eighth. of an inch...
Reply:Originally Posted by weldbeadit's only an eighth. of an inch...
Reply:What the... Zap, did someone just turn the bearing diameter down and use a different pillow block? That's just different...Matt
Reply:"rubber covered and weighs in at 4450 LBS" with an additional "pressure roller that's under 3 tons of pressure" with a downhill gap on one side will eventually cause that rubber cover to literally pound off.especially when you figure 3.937 - 3.682 = .255 which is a 1/4" gap .    Not sure what the over all length of the roller is but that thing should have been  making considerable chucking noise that someone should have noticed. Your right Zap this little project ought to keep you employed for awhile.  Make sure they have a FAT wallet$$$$$$$$$$$ and plenty of beerCo-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:What does the size of the bearings have to do with it? As long as it was setup parallel to the pressure roller the bearing size wouldn't matter. I am just saying that it wasn't the bearing that caused it but was the people who installed it and never aligned it.Archer
Reply:Zap, does that shaft run on pillow blocks or flange mount?                                       MikeOl' Stonebreaker  "Experience is the name everyone gives to their mistakes"Hobart G-213 portableMiller 175 migMiller thunderbolt ac/dc stick Victor O/A setupMakita chop saw
Reply:Originally Posted by Archer_2929What does the size of the bearings have to do with it? As long as it was setup parallel to the pressure roller the bearing size wouldn't matter. I am just saying that it wasn't the bearing that caused it but was the people who installed it and never aligned it.Archer
Reply:I have no idea but will guess pillow block..This is gonna get good..Pillow would explain the rubber getting torn off..It will be recovered when I'M done with it..Yay.I can't wait....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by specter    Not sure what the over all length of the roller is but that thing should have been  making considerable chucking noise that someone should have noticed. Your right Zap this little project ought to keep you employed for awhile.  Make sure they have a FAT wallet$$$$$$$$$$$ and plenty of beer
Reply:Boy you've got to luv it when they come in prior to end of day with a project like that trying to explain they don't know what went wrong but they need it fixed ASAP.Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:Zap, You definitely aint seen it all unless you saw the frame repair that was done on a 85 Nissan pick up that I towed in with a bad fuel pump today. Bed frame and 110 flux core, sounds scary enough without pictures doesn't it?. I'll post pictures later when I download them from the camera in a new thread.I am what I am, Deal with it!If necessity is the Mother of Invention, I must be the Father of Desperation!
Reply:Originally Posted by dabar39Zap, You definitely aint seen it all unless you saw the frame repair that was done on a 85 Nissan pick up that I towed in with a bad fuel pump today. Bed frame and 110 flux core, sounds scary enough without pictures doesn't it?. I'll post pictures later when I download them from the camera in a new thread.
Reply:Well the print for repair  was on my box this AM...Both sides are supposed to be the same..3.937..The longer side is .008 under and that will need welding..(I ain't messing with the keyway)The shorter side I will sleeve..Pics when I get home.....zap!Last edited by zapster; 11-03-2010 at 06:02 AM.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:Well Zap I can certainly relate to your feelings about tackling a key way.Here is one I recently did on a 4" Hydraulic cylinder from a log splitter. The owner had broken off the end of the retaining ring in the key way and this prevented removing the ring the ring. The ring had to come out of the key way in order for me to rebuild the leaking cylinder.Picture 1 shows I had to use a 3" air cutter to cut away the key way above  the broken end of the retaining ring. Yes that ring runs all the way around the cylinder in that key way and locks the end cap on the cylinder over the hydraulic cylinder piston.Picture 2 shows the portion of key way cut away and the retaining ring removed from the cylinder. Had to pry up on end of the retaining ring and clamp onto it then gradually spin the end cap while pulling on the ring in order to fully remove it from the cylinder key way.Picture 3 shows the fully restored cylinder and key way with the new retaining ring installed.What the pictures do not show is the welding done to restore that key way.  When welding on the cylinder to restore the original key way the weld spilled into the key way groove. That spill over and restoration of the key way groove was pure hell using the 3" air cutter and a dremel tool. Attached ImagesCo-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:Zap, I checked the bearing interchange for pillow blocks with 3 11/16"/3 15/16" inner race dimensions and center heights the same.It appears that someone may have had a good idea that went very bad if the pillow blocks aren't matched correctly.I circled the center height of some different bearings and you could really get in some trouble here. I still can't believe someone assembled all this and didn't notice some mis-match or such.If the cylinder is mounted on take-up (sliding) bearings and someone sets the height that poorly it'll be back... Wonderful...(EDIT) Specter, that looks like a handfull for sure! Good jobMatt Attached Images
Reply:Thanks for the charts there Matt very handy!As we continue..I gave it a once over this AM and found some rather amusing "Fixes?"..I found a bunch of these below on the ends of the rubber..Both sides..And a bunch of these..Seems like someone had this brilliant idea of how to keep the rubber from sliding off..Stainless 3/8" Allen Socket Head Screws..There are a bunch under the rubber where you can barely see them but they are all bent also..Did NOT work apparently..But anyway that's not my department..Here is the long journal with the keyway..I am only going to weld from the key to the seal area because that's where the bearing goes..Next post.....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 working on the short side..We need a sleeve.Let's saw off some tubing..Machined to shrink on by .008..Installed..Still red hot..End weld area..Welded and the seal surface is welded also..Next post.....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:Here is the bummer part of the day..I was just finishing the weld on the short end and suddenly there was no more power..It seems like the power cable was twisted around one time too much and something had to give..So a trip to the LWS and I picked up one of these..All better now so take care of those hoses!They can and will crap out at the most innopertune time..Tomorrow it's the long journal repair.Lot's 'o welding needed.....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 doubt that all those capscrews were put in on night shift while nobody was watching...I get the feeling sombody "left the farm to the kids" but forgot to teach them how to drive the tractor...This is just amazing... Good fix so farMatt
Reply:Well here is the welding all done pics..Long end...All the welds were done with 1/16" 70S-3...For once I do NOT have to do the machining!!!!!The boss will do this one himself!I'll take pics of his progress......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:how did you rotate 4500 while welding?miller syncrowave 250hobart handler 140home made 400 amp engine driven in progress...
Reply:Originally Posted by jdchmielhow did you rotate 4500 while welding?
Reply:Zapster, I want to be you if I grow up.I can remember in the 7th grade my mom said "people will offer you drugs" by the 10th grade I was like, "where the hell are these people?"
Reply:Originally Posted by joefitzZapster, I want to be you if I grow up.Impressive repair! Can't wait to see how it looks after machining. Take tomorrow off, you deserve it
Reply:wow, nice job. what did you do? weld all the rows on like a 5th of the diameter or so & then rotate it & repeat? I can't imagine you rotating it while welding... either way that's a crazy job, more beads in a day than many would do in a month, you must weld like a robot by now 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 zapsterHere is the bummer part of the day..I was just finishing the weld on the short end and suddenly there was no more power..It seems like the power cable was twisted around one time too much and something had to give..
Reply:Originally Posted by jakeruDid you have a coolant leak when that happened, Zap?Was that a CK "superflex" power cord that failed?
Reply:Originally Posted by turbocad6wow, nice job. what did you do? weld all the rows on like a 5th of the diameter or so & then rotate it & repeat? I can't imagine you rotating it while welding... either way that's a crazy job, more beads in a day than many would do in a month, you must weld like a robot by now
Reply:almost a shame you have to machine those welds. Oh well, we have the photos.
Reply:Can you tell me why you chose to TIG weld as opposed to another method?Thanks,
Reply:It's either TIG or fluxcore with a 110 machine or 7018 Stick that would get spatter everywhere and fill the whole shop with smoke..I always tig everything (99% of the time) anyway..To do a job like this you need to know that ALL of the bearing surface got the "Treatment" and will clean before you put this in the lathe to machine it..Stick leaves that margin of error where the flux will get in the way of complete coverage at times and I am NOT welding this twice.110 fluxcore..Well that is self explanitory why it is not even considered.....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:No MIG with gas?
Reply:Originally Posted by engineer1984No MIG with gas?
Reply:I feel your pain zap. I used to have to do all the build ups at a shop I worked at. IT SUCKED! 100LBS of 7018 every other day. Oh dont forget the noisy needle gun to put the icing on the cake. Tig seems like the way to go. Looks like another good weld job.