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Thread: Worst Shop Day Ever
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23rd May 2017, 08:16 AM #31Pink 10EE owner
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Well it is good to see a bit of vibrant colour at one of those show. Speaking of light red, when I was pulling handy bits off this lathe what colour should I come across that the inside of the castings was painted? But a light shade of red. Similar to that Southern Cross diesel you have there in the photo.
Gold, the colour of choice for the discerning person.
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23rd May 2017, 10:43 AM #32
His overhead crane is a 15 ton unit , he did say that he should have replaced the cable .
At no time was he under it and he had the choice of electric hoist or the much smoother chain driven , he chose the latter .
It is easy to criticise someone , did anyone bother to read his comments about moving it he clearly said never again with such a heavy load.
His rebuild of the building is a credit to him and yes he did make a mistake by not spending around $1200 for a new cable .
I would rather not be critical of someone who is actually getting the job done , also it was good of him to post the video of the drill and the cable breaking , to show people what can happen .
Michael
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27th May 2017, 12:30 PM #33
Brian has started repairing the damage to his drill , it should be good as he is particular with machinery .
I have watched most of his videos and have picked up a few ideas .
Michael
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27th May 2017, 10:42 PM #34Diamond Member
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28th May 2017, 12:36 AM #35Golden Member
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In his follow up video I think I recall he mentioned welding the broken casting with nickel rods, I didn't know this was possible, I thought cast iron would crack unless brought up to temperature before welding, usually done in a forge, does having a large mass to dissipate heat make the difference?
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28th May 2017, 01:17 AM #36Diamond Member
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I'm not qualified to give you a definitive answer, but there are a couple of factors which may influence the result. Firstly the material may not be a cast iron of normal composition, it may be more of a cast steel. I don't know how that would influence the welding repair, but my guess would be that it would be easier to weld.
Also I have heard that if you peen your welds as you go, you can stress relieve and help prevent cracking. Anecdotally I understand that you can even use conventional rods, and I think that Brian mentioned using 7018s, which are usually used on medium carbon steel, - I think, but stand to be corrected on all this, and if you use a needle scaler, you can repair cast iron if you know what you are doing. Like I said, I could be completely wrong in all this. I do think that both preheating and a very slow cooling post welding would be best if he can manage it, less chance of cracking and less weld distortion being the benefits. Nickel rods would make it easier to machine if that is necessary for a part, because the formation of very hard carbide nodules would be much less likely, but not impossible as I understand it. If we're lucky a boilermaker or welding technologist will put us all straight if I've written a pile of drivel.
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28th May 2017, 10:57 PM #37Pink 10EE owner
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Well as far as his repair goes, I do not think I would want to be anywhere near that drill when he uses it, the motor on that drill is huge. I would hate to be anywhere near it should the weld fail.
I have welded a bit of cast iron and it can be done successfully done, but not the way he is doing it. I would think to do a proper repair would be a big undertaking. Arm stripped down and removed from the column, then the casting prepared for welding, then welded with the proper procedure, then the machine reassembled, if it has not warped from the pre-heating and post heating process that has to be done for cast iron.Gold, the colour of choice for the discerning person.
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29th May 2017, 10:34 AM #38
Time will tell and he is probably like me trusts his weld and will test it .
If we all doubted anything , nothing would get done .
Michael
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29th May 2017, 12:40 PM #39Golden Member
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29th May 2017, 06:28 PM #40
He isnt just tacking it together, he proposes to cut out a pie shaped section and after grinding it with a good v , the metal which has been cutaway will be replaced with weld, long , hard process .
From the look of the small arm which he has already welded the castings may be steel as that small piece welded ok after he ground a deep v and fitted it back together , hit it fairly hard after welding .
Although when a press frame broke at a factory that I was a maintenance person at, we did not bother to weld the grey casting it was used as a pattern for one that was cut out of a 4 inch plate and the two cutouts were welded together to make up the required 8 inch side frame .
This heavy piece was then machined again using the cast iron as a pattern for bore sizes and cutouts etc , that frame would not break .
If it was my drill I would seriously explore making a steel weldment replacement of the broken casting as cast iron has never impressed me in areas of stress like support and load bearing structures .
I doesnt like shock loading even when not broken , steel might bend or twist but not snap .
Michael
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29th May 2017, 06:29 PM #41Most Valued Member
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I haven't watched the repair so have no comment other than I agree about the difficulty of a proper repair. Running beads of high nickel rod is unlikely to be a satisfactory long term repair unless the break has been ground to a deep V form and then built up again to achieve a near 100% full penetration weld. I'd do a double-V weld prep from both sides myself. Pre-heat and slow post-weld cooling.
It can be done but it's a tricky job.
PDW
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30th May 2017, 09:16 AM #42Pink 10EE owner
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It goes along with the rest of the videos.
Uses 7018 welding rods to weld cast iron. Angle grinder with the guard removed. Uses the drill box table as a welding bench and as an anvil.
I am not normally that negative with people giving it a go, but when it seems to be one thing after another it makes you wonder.Gold, the colour of choice for the discerning person.
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30th May 2017, 09:29 AM #43Most Valued Member
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OK you've told me all I need to know now. I'm travelling ATM anyway so limited bandwidth. Sydney in another 4 days or so.
I've got an old radial arm drill box table to collect one of these days - the drill got scrapped. Probably use it as a welding table myself but I wouldn't use a functional one that way. Be like using the big platen on my O type HBM as a welding jig table. I'd kill anyone who did that.
PDW
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30th May 2017, 09:54 AM #44
As he said in the video it is not possible to grind inside the slot with the guard on the grinder, he said himself do not do as I do
??
I have also welded cast iron with mild steel rods and then used a scale gun to peen the living daylights out of the weld as it cooled , that part is in use after ten years to the best of my knowledge .
Often its is not practical to do what you are supposed to do but if you work slowly and be as sensible as possible ,even with some "safety concerns" the job can be done .
Accidents often happen because people dont think the job through and work slowly to make sure that the repair is strong and not a waste of time .
I am also guilty of removing a guard on a grinder to grind inside a slot so that the parts would mate without binding as it was over 100 klms back to the shop with a milling machine so I took the risk and saved hours .
Michael
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31st May 2017, 09:23 PM #45
He has started the repair and I am going to watch the progress with interest .
Michael
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