Cast gearbox ear

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I had a forklift in for some work. The steering box is broken away from the ONE bolt that holds it.First I did a spark test with the 4.5" grinder.  It was cast steel. Nice long yellow sparks and quite a few.Grind it deep.Here is a profile view.  I went too deep, I burned through what I left. 3/32 7018 out of the oven, 90 amps.  Rod was kinda long, so......Last edited by David R; 12-17-2007 at 07:27 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Notice the nice clan ground.I chipped and wire brushed between every bead.This is a an old towmoter.....The real thing with no power steering.  The steering wheel is bent.  I put more back than was there. DavidLast edited by David R; 12-17-2007 at 07:24 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Not being a wise ***, seriously trying to learn here. My question is: Werent you worried about that built up grease?I liked how you put more material in it that it came with, they'll never have problems with that ear again.What are all those rods laying there also??Thank you!!- Jason
Reply:Originally Posted by Jasondt2001Not being a wise ***, seriously trying to learn here. My question is: Werent you worried about that built up grease?I liked how you put more material in it that it came with, they'll never have problems with that ear again.What are all those rods laying there also??Thank you!!- Jason
Reply:Ohhh ok, I saw the tight spots in the pics and wondered how in the world a set of hands would get in there. I didn't see "GREASE" i just saw some oil on the sides, and it made me wonder.Like I said, I'm in no way trying to hurt your work or anything, i'm honestly just new and trying to learn not makin enemies.- Jason
Reply:Speaking of old tow motors and steering and such, we have a 5k Champ that runs full hydraulic steering.  This morning, after getting to work, we found that on saturday the main ball joint had snapped off at the hydraulic ram connection point. I whipped out some comment like, "We can fix it!" So my boss asked me if it could be welded. I said, "Sure, hehehe, in theory." I will have to try and get a picture, but don't hold your breath! Actually I can just see the shiny shaft in this photo just under the left red and white reflector sticker.The part has the ball on one end and a threaded shaft on the other, a lot like a trailer hitch ball, and the threaded end snapped off leaving the ball stuck in the socket end and the hydraulic ram hanging down on the left.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:That's good, David! Tough place to get into for welding.......as far as you went.What that single bolt tab is telling us when it broke, is that it wants a gusset plate, in addition to welding the crack. The lack of a casting gusset in this area, setup the scenario for the tab to break.Below are rough lined pics of what I'm yappin' about:top view:        http://www.weldingweb.com/attachment...1&d=1197961229                   side view:http://www.weldingweb.com/attachment...1&d=1197961244Heavy fillets into beveled edges of the gusset will suffice.The steering gear on tired, old abused lifts really takes a beating. That's also what'soccurring. If this tab hadn't broken, then the pitman arm of the steering box would have bent, and/or the outer rods. I've seen all of that. I'll bet doughnuts the steering gear has other problems, and this is a hard tire being driven on rough surface, or a soft tire that's getting run thru ditches.Suggestion: Anytime some breaks, look for 'why' did it break? (the single mount tab, was/is a piss poor design from the git-go. Typical forklift engineering.)If reinforcement will help, how can that be done, without affecting form, fit and function?If a repair shop does the above, they consistently produce, either permanent or much long lasting repairs than other shops. This is one of the ways you GROW CUSTOMERS.I do not want to see customers coming back into my shop, to repeatedly fix the same part.....and they don't. (I don't think they hanker to do that-either! Would you?) Attached ImagesBlackbird
Reply:good job Dave that should holdChuckASME Pressure Vessel welder
Reply:Dave powelson,I did put a small piece of 3/8 plate in the front of the gearbox welded to the mounting piece of the frame to keep the box from moving.  You can see it in the pic just under the "settings" or pic of my welder.Thanks, I was thinking of welding the wole stinkin gear box to the frame.  I tightened the bolts, adjusted the gear box and tried to fill it with oil.  It had already been filled with axle grease.  That is an OLD trick I used to use.  Screw a grease fitting in the fill plug and pump away.  It will never leak again.Jasont2001, these pics are to show that kind of stuff can be done.  DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:nice fix David great job as always  Creative metal Creative metal Facebook
Reply:Originally Posted by David RJasont2001, these pics are to show that kind of stuff can be done.  David
Reply:Originally Posted by dave powelsonThat's good, David! Tough place to get into for welding.......as far as you went...Suggestion: Anytime some breaks, look for 'why' did it break?...
Reply:I like that welder , lights up and everything. Which one is that?Looking good.
Reply:Denrep, there was NO shim. just the part sticking through the mount used to fit real well.  I added the shim.Bikespot, its a Linconl invertec V 350 PRO (  ) with advanced panel.  Gives me a woody.Thanks for the complements.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:I called it a shim, I meant that "flag" under the mounting ear. It's been there since day one, or at least since the last paint job. Looks like that flag caused an offset and prevented the gear from mounting flush and  perpendicular, to the mount plate.Don't get me wrong, I wasn't second guessing the repair decision. It'll probably turn out to be the last time  the gear was touched by human hands! Just a response to dave powelson's deeper digging.
Reply:Gotchya.  I see what shim you are talking about.  Most gearboxes have 3 bolts holding them on.  1 isn't enough.David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by David RI ground off any paint, dirt or grease where I was welding.  If you mean it catching on fire, no I wasn't worried.The rods are the "butts" from having limited access.  That is what it took to fill the groove and more.David