Cast Iron Repair Job: Machining a Replacement Casting and Brazing in Place
Жүктеу.....
Пікірлер: 172
@byrnejr5 жыл бұрын
Like my grandfather used to say. If we all liked the same thing . Everyone would be chasing your grandmother! Nice job!
@Hoaxer515 жыл бұрын
I liked the one part of the video where you can see you turning the hand wheel on your x axis. For us that are not that experienced, I liked that we could see how fast (or slow) you were feeding the part into the cutter. I wish that all the machinists would show more of that in their videos, on the milling machines and on the lathes. Or all of their machines. Thanks for sharing, and nice job on the brazing.
@DanielGouldingnavy5 жыл бұрын
I enjoyed your talk about why you gas braze, my opinion is there are hundreds of "right" ways to do a job, but the best way and usually the most successful way is the one you are most comfortable with.
@davidmotoman49565 жыл бұрын
Ive always found Torch Brazing to be the best, specially as you said Keeping a lot more heat into the Cast iron. My dear old dad showed me this more than 50 years ago on a Large Old Dawn Vice which i still have and still working like a Charm to this day. regards Dave from Australia
@morriewyatt6234
5 жыл бұрын
And as their old slogan used to go: "Make Dawn your only vice." Also from Australia.
@geoffmorgan6059
5 жыл бұрын
Brazing is the best way to go as long as the section is not really thick. An additional way to secure cast iron is with the "Metal-lok" or "Metal-lace" proprietary systems. For extra heavy sections (like the gear box on a Caterpillar D9). It works, but brazing is still used along with Lab Metal or Belzona, etc. You could pin this casting if you are concerned about bending loads, also helps with alignment. Of course you have to pin first. Good job!
@boldford
4 жыл бұрын
@@geoffmorgan6059 One of the problems with welding cast iron is the additional heat converts the iron into very brittle carbides. This is avoided with the lower temperature used in brazing.
@windyhillfoundry59405 жыл бұрын
Looks great Keith, sure glad I didnt have to cast the whole thing😁
@windyhillfoundry5940
5 жыл бұрын
@John Doe thankyou, I try my best
@phillipyannone31955 жыл бұрын
I completely agree with the brazing technique but I believe the preheating should extend to the entire casting.
@andreturnbull12595 жыл бұрын
Your brazing experience is valuable to novices like myself. It would great if you put together a video or two with all your tips and tricks on brazing. I have struggled with brazing but would like to master it. Great KZread channel by the way. Thanks for your efforts.
@tracylemme1375
5 жыл бұрын
I have found that most problems people have with brazing is the lack of heat. Preheat then preheat some more. Remember that the heat conducts to the entire casting. My dad said when choosing a tip, use one that is two sizes larger than you think you need. If it isn’t hot enough, you will fight the process until the very end when the casting finally becomes hot enough.
@bookerol5 жыл бұрын
That is a big hunk of cast to preheat. I was surprised that the woodworker, in you, didn't scribe that joint in with dividers. Looking good though... can't wait for the finish.
@AffordBindEquipment
5 жыл бұрын
As a journeyman cabinetmaker, I agree. it could even be scribed from both sides to get the taper from the broken piece.
@bgcal50cal5 жыл бұрын
Great job brazing up the joint. I have been gas brazing cast iron parts for many years. The idea of an old oven to soak the whole part to 500 degrees over nite is what I always did on large cross section parts. I finish joint with filing surface vs. grinding prior to brazing, Was told years ago that grinding draws out graphite to the surface and inhibit good adhesion between parts. Great seeing old parts saved instead of sending to the dumpster.
@brandenpatterson27762 жыл бұрын
Keith what a beautiful job on the repair glad I got to go back and watch this one!
@BROCKWOOD645 жыл бұрын
Jon Kaase in the 2015 Vintage Engine Dyno Challenge quote, "I've got more money in the 10 pounds of special welding rod it took to modify the heads than I do the actual cost of these brand new heads." That's reason 1 for me to stay with gas brazing cast iron! Great job, as usual Keith!
@july8xx5 жыл бұрын
What your shop needs is a good used oven, soaking large cast iron parts over night makes brazing them a lot easier and reduces heat warp as the entire piece is close to the same temperature. Ten years ago I picked one up from Habitat for $25.00, as a side benefit it can still cook a frozen pizza for lunch.
@dhc4ever
5 жыл бұрын
What sized oven did have in mind? I can see the point for small pieces say up to 15 to 20 inch, but the bit he's currently working on, not a hope, its got to weigh 300 lb. You are right about the pizza idea though. Cheers
@july8xx
5 жыл бұрын
@@dhc4ever It is a used Kenmore 30” wall oven, it came with a broken door handle and a burned out upper element, $25.00 from Habitat. You can get a 24” wide and 20” deep piece in it, longer if you take the door off and wrap the front with some Nomex blankets.
@SuperAWaC5 жыл бұрын
one of my favorite things to look at is freshly machined cast iron
@hendrikcattoor5 жыл бұрын
👍👍👍Keith, I've seen you do several similar repairs, and every time you surprise me with the perfection, love your videos. best regards from belgium.👍👍👍
@NikColyerMachineWorks5 жыл бұрын
That was a braze job and a half. Came out great!
@buckburton73182 жыл бұрын
Great Job, I know nothing about what you do, maybe that's why I find it so interesting.
@keith73z285 жыл бұрын
The more i get to observe you Brazing Cast iron the better. I recall from some years back that when i tried stick again after many years away from it, noticed I was more adept at it after many thousands of hours under the weld helmet working and watching that puddle during production Mig Welding. Exellent project planning. I kinda consider myself as part of my tools, that is like what I am more able with ME low on "Gas". One of the most enjoyable skills that I learned in the Weld dept. of a fab shop I worked at, was learning how to fix others mistakes. AND have it be a good part. I don't always say it but great effort and also a good product; Video and a good Part.
@andyZ3500s5 жыл бұрын
Looking good Keith. You did a nice job on the preparation, getting everything linded up and looking straight. By the time you clean the top up and get it painted nobody would ever know that it was broken. Looking forward to the next video. Thanks Andy
@ladamurni5 жыл бұрын
Most of the time I have no idea of what you are doing, your explanation helps a lot and I can see the craftsmanship you are having. That is what makes it interesting to watch your videos. My father (the lord has his soul) used to be a black smith maybe that's also why I like to watch your videos. Thank you for the upload Keith!
@waiakalulu35015 жыл бұрын
Great job, Keith!! I'm delighted with seeing this repair putting this piece back into useful service.
@richardcurtis5565 жыл бұрын
I've seen you braze cast iron before and I think your judgement on this job is spot on. I also like the idea of finding an old oven to preheat/bake pizza - has the added advantage of baking out any oils that might bugger up the brazing.
@d.mushroomhunter35285 жыл бұрын
Hey Keith it's me mushroom hunter.. I think I confused a whole bunch of your viewers when I was running my mouth off about the rebuild.. I'm kind of hoping that you got it.. but just in case you didn't. I was just making a reference on how much I appreciate the master craftsmanship that it takes to be a skilled machinist, compared to what I do as a trim Carpenter.. I love your videos.. keep them up.. and I still hope to watch the rebuild enough times to comprehend the accuracy and dedication to precision that it requires to do the project you're doing.. most people cannot even comprehend 1/64 of a piece of paper.,... good on your brother!! cheers!!
@morelenmir5 жыл бұрын
The old adage of 'Grinders and paint...etc' never fails to apply does it! I hardly need to say it, but simply *excellent* work Keith! How you could get that rough casting so well matched to the broken piece is simply beyond me. I would have messed that up in three hundred different ways. Many, many thanks as always for the video. I look forward to seeing the next section of the repair.
@petersimmons7432 жыл бұрын
Love what you are doing and because I learn so mutch.
@chrismate28055 жыл бұрын
It looks like a good cast and that was a good braze, like this repair. If you grind the weld a bit and then sandblast the whole part, maybe it blend in good and hardly noticeble after painted.
@hughedavid15 жыл бұрын
Keith I agree whole hearted that flame brazing is the way to go on something that large and thick. I have been doing that sense I was 9 you ears old and have worked for a company where we repaired large mechanical press rams and knuckles etc! . We always flame brazed and I have never had a failure to my knowledge. Good choice. I have also made a many repair using Ni - Cad rods and others but you still have to maintain a good bit of heat so I am confident you made the right choice.
@DavidChadwell5 жыл бұрын
Keith, do you have a profile gauge? It would make your life a lot easier for matching up parts like that. You set the profile of the existing part in your profile gauge, then put your new piece in place until it contacts the existing part as you had it, measure how far your part sticks out along that outside straight edge, then locate your profile gauge to the correct dimension from your existing part edge and trace your profile gauge onto the new part for a perfect edge geometry. This is useful for all sorts of jobs, even tile floors and millwork.
@N1gel
Жыл бұрын
Or a pèncil and sheet of paper.
@gvet475 жыл бұрын
Gave me a flashback of when I was watching my father-in-law braze an Old International 101 combine variable speed pulley half to re-build and bore the pin holes it road on. He was sitting with the pulley in a stump mounted vise, somewhat between his knees. A hot molten bead ran out and down the slope of the pulley and right in his half open laced boot. Big 6'-6" 280 pound man pulled that boot off tearing right out of the leather. Had went all the way to the sole of the boot and cauterized the wound on the arch of his foot. Last time I seen him braze anything.
@steveg4iwr5 жыл бұрын
At the end of the day its your job so you do it how you see fit. 😊 I love the videos having been an electrical / TV engineer this me a different sort of engineering to learn.
@jimkodysz54045 жыл бұрын
Nice job Keith! I've brazed a lot of exhaust and intake manifolds, and I've never had one fail!
@timelessengineering4 жыл бұрын
G'day Keith always great to watch you perform tried and proved methods. Hand made patterns to flame tip brazing. Like they say when you're on a good thing stick to it.
@donmittlestaedt11175 жыл бұрын
Love it. Thanks for doing it on video. I look forward to the second episode.
@kmbrady1a5 жыл бұрын
Thanks for coming back to this, I was thinking I missed a video
@fox322235 жыл бұрын
Didn’t we see a video of you standing next to a 20” DoAll Band Saw a few months ago??? That would have cut that down to size with no trips to the museum! I love your videos!! Can’t wait to see it all together!
@bcbloc025 жыл бұрын
You are half way there! It looks like a very proper repair to me.
@dananelson4795 жыл бұрын
That's a pretty massive part to braze. Thanks for sharing. Look forward to seeing it finished and set up.
@johnwarkentinnikiskialaska83644 жыл бұрын
Great job 👍
@PhilG9995 жыл бұрын
Years ago I had an "interesting" brazing project. Somebody in shipping knocked a scale off the table and the cast iron base shattered! Wasn't critical to the operation of the scale more to cover up the inner workings. 1/4" thick or so. All these triangular pieces had to go back together like a jigsaw puzzle (and that took a while). Beveled the mating edges and started brazing. The tricky part was working in different areas so the heat from where I was working didn't melt the other brazed joints. Did one per day and let it cool overnight, then did one FAR away the next day. Got about halfway through and got laid off so I don't know if anyone ever finished it... :(
@johnstrange67995 жыл бұрын
Thanks, Keith.
@aserta5 жыл бұрын
Yey, the table is getting fixed. Been waiting for this one so i can soak up some knowledge. Have a few repairs myself, and i've been chickening out of them for a reason or another.
@southjerseysound7340
5 жыл бұрын
I don't know what you need to fix but take a look at lock n stitch. Since using it I was amazed.
@DavidChadwell5 жыл бұрын
Those deep cuts had me on the edge of my seat, I was ready for a broken end mill or clamp slippage.
@boldford
4 жыл бұрын
Made my bum clench too.
@garywills56825 жыл бұрын
I agree brazing is the best , welding in opinion allows for air and water migration if not solid thruout. And ive been around longer then most on here preaching the welding. Tig may be really good with the bronze filler rod from my perspective it should flow in to the pores of the metal like brazing rod with flux, borax.
@jasincolegrove66515 жыл бұрын
I’m alright with doing what you’re comfortable with. I had no experience and when I learned to weld cast iron. But I have also seen some brazing repairs hold the test of time. You were spot on with your assessment. Thanks for the video, like to see what’s left up your sleeve
@curtisvonepp43355 жыл бұрын
If you have a veary large piece to Braze for added strength drill and tap studs at different angles in the gruves use Borax flux generiously and use plenty preheat burners on the bottom castings 🙌🔥
@kerrygleeson44095 жыл бұрын
Great job Keith thanks for sharing 👍
@CrimeVid5 жыл бұрын
Brazing is the way to fix cast iron, I’ve asked old press operators when the press they have spent their life on was repaired, the answer is always “before I got here” !
@63256325N5 жыл бұрын
Beautiful job! Thanks for the video.
@ZaphodHarkonnen5 жыл бұрын
That harmonic. Wow
@WoodNMetalWorkshop5 жыл бұрын
Great video as always. The only thing I would have done differently is I would have preheated the parts on the charcoal grill to about 350. Saves a lot of gas. Kent
@jameshatfield7634
5 жыл бұрын
I agree to that,more even heat.
@WoodNMetalWorkshop
5 жыл бұрын
@@jameshatfield7634 That too. I used to have an old electric oven in the shop for preheating parts and small powder coating jobs, it was nice to be able to take a freshly brazed part and toss it back in the oven for a controlled cool down as well. I may have to check Craigs list for another one.
@Watchyn_Yarwood5 жыл бұрын
Excellent brazing job!
@SpiritWarriorOne5 жыл бұрын
Been waiting a long time to see how this turns out looks great so far Keith
@shortribslongbow53125 жыл бұрын
Very interesting video thanks for sharing.
@catfishgray6515 жыл бұрын
GREAT JOB KEITH...
@jasonhull5712 Жыл бұрын
I have a cross slide I need to fill in where its pulled up and busting. Missing chunks. I'm thinking this is great inspiration to proceed with the repairs.. thanks Keith.
@AmericanJusticeCorp5 жыл бұрын
That is a massive piece of metal to braze. I can see how you would have trouble keeping enough heat in it.
@johnapel28565 жыл бұрын
Nicely done. I wondered like several others why you didn't try and get heat into more of the part before you began brazing, but I guess you just had to be sure you could keep the repair area hot enough while brazing and the rosebud supplied enough heat? Thanks for the video.
@vicpatton52865 жыл бұрын
Hi Keith Very nice piece of work and quite enjoyable to watch while you expended all the effort. Sure the base will serve you well for many, many more years. The complexity and quality of those vintage machine casting is something I always find impressive. :-)
@mrbrown34622 жыл бұрын
I know this is an old video but I do alot of old farm equipment repair which consists of a lot of cast repair we don't have time most of the time to heat and weld and reheat and pack cast to do so called proper cast repair and most of the time the piece is still on the tractor or implement. If it's a no load item I always braze it I have cast things I brazed 30 some years ago still holding up still doing their original job, If the part is something with a load or is in contact with ground such as tillage implements I weld them back together with 308 stainless rod bonds cast nicely and wears good in the abrasive dirt I've never once have had a repeat repair on cast parts welded with stainless many of the old timers did it and many of their repairs are still holding strong see them everyday just about. You'll of course have your keyboard warriors tell you brazing or welding cast with stainless is wrong it will never hold it's weak and so on because they have never done it or they can't weld period or they never cleaned their parts properly or someone told them it's wrong and doesn't work. I have a Cat D7 dozer that was abused it's whole life in a rock quarry that machine is pretty much all brass and stainless with all it's welds and cracks that were repaired over it's life but the machine at 73 years old will still go out and push dirt all day long like it was built to do.
@Just1GuyMetalworks5 жыл бұрын
No school like the old school 😁. There's a little too much tig fluff out there anyways imho 😊. Nice work, Keith.
@boldford
4 жыл бұрын
The heat is too localised with an arc.
@jdgower15 жыл бұрын
Couple of comments from one old school maintenance man to another: If brazing gets the job done for the intended purpose, why weld?!? It's kinda like going to prom in high school. If you can take your girl in a ragged out AMC Hornet and get as much "action" either way, why rent a limo? Yeah, I drove a Hornet in high school. It worked just fine for me... As for torch versus TIG brazing on cast iron of parts that big; Torch all the way. With cast iron you HAVE to spread the heat before you braze or weld. the important thing is to keep the heat differential down between the part and the weld/braze area. You kinda want to 'feather' it out. Unnecessarily changing tools to get a job done is frowned upon in the real world. It's also important to evenly cool the piece down after brazing, and passing the rosebud over it every once in a while while it cools helps to relieve any stress imparted by the brazing. The blanket helps a lot, too. Interesting trick taught to me by my mentor in industrial maintenance is what I call the "Rosebud Trick". If you take a rosebud oxy acetylene tip and light it on just acetylene, you can coat a part in pure carbon. Interestingly enough, once that part gets to about 400 degrees F, the carbon on it wants to make CO2 with the ambient oxygen in the air. Even more interesting is that 400F is about the temp you kinda want to pre heat cast iron and aluminum to, before brazing or welding. Long story short, that torch in your hand is literally a 'multi tool' if wielded right. It is not only a pre heater, it is also a pretty precise temp measuring device, and it is the tool you can use to weld/braze. Side note: If you want to case harden some steel, you don't need to buy Carbonite case hardening powder. Just use a rosebud and switch the oxygen off to add some elemental carbon, then on to raise the temp. Rinse and repeat. It's slower in a sense, but quicker over all. You're not sprinkling powder or dipping parts in a can. You're just turning a valve every once in a while. Oxy acetylene torch sets are golden tear drops of God's sweet love to old school maintenance guys. Molon Labe! Come and pry my Oxy Acetylene kit from my glove covered hands!
@Landrew05 жыл бұрын
If only more of us would get things repaired instead of throwing everything out.
@ohammouda
5 жыл бұрын
@Barry Manilowa If you're sick, go to a fucking doctor don't complain here.
@organbuilder272
4 жыл бұрын
@Barry Manilowa Barry, That is really uncalled for. If you are a fan of Keith's and other similar sites, I think you understand how Landrew feel. He's not sanctamonious, he is making an honest comment. Okay...
@bettytherussiantortoise2808
4 жыл бұрын
Barry Manilowa stop acting like a chromosome deficient pile of crap and how about go crawl back under the rock you crawled out from
@edwardkawecki81015 жыл бұрын
My GO to is also brazing when I can put the preheat into the c
@edwardkawecki8101
5 жыл бұрын
My go-to is also brazing when I can safely put the preheat and the heat into the cast iron part. Second is a nickel or cast iron stick rod if looks don't matter, but I have had a lot of great repairs on cast using LH 7018 welding in very short runs and peening the heck out of them immediately and skipping around. Weld matches very good and keeps the heat low enough not to distort anything. Always worked best for me when having to weld mild steel to ductile material like manhole risers for asphalt road paving. Nice video Keith, thanks.
@outsidescrewball5 жыл бұрын
enjoyed...great discussion/build...
@rickpalechuk44115 жыл бұрын
Those were some big cuts. Thanks for sharing Keith, Cheers
@godbluffvdgg5 жыл бұрын
Nice work!
@JohnnyUmphress5 жыл бұрын
I'm the same way, my goto method is brazing if possible. I am much better at brazing than welding.
@southjerseysound7340
5 жыл бұрын
I used to be the same until I used lock n stitch. Now it's my go to although might've brazed this too.
@dingui8755 жыл бұрын
Good job!!!
@firearmsstudent5 жыл бұрын
13:00 RIP headphone users
@elsdp-45605 жыл бұрын
THANK YOU...for sharing. Enjoyed.
@dessilverson1615 жыл бұрын
Nice one. My choice of brazing method as well. Des.
@dillydallydollcomachineand82465 жыл бұрын
Great Job on saving a old piece of great equipment !!!!!!
@davidhoward22375 жыл бұрын
waited up for this nice
@dougguynn26225 жыл бұрын
great job, and enjoyed
@paulkoomen52625 жыл бұрын
The company I work for has motors with inter graded gear boxes. That have circular cutting blade on them as they run on a track and have a hard stop they brake the ears off . This was due to the wrong size blots to hold them down I found out later when I took it apart I was asked to look and see what was wrong I saw that the ears had broken off and told the lead Hand and he said to shut the machine down Untill we get a unit. I told him I can fix it give me two hours and we will be running .As the gearboxes are cast steel I brazen the ears Back on and we where running. Only to find out their where three other units all the same , so I fixed them all that was their and saved the company $ 1500.00 dollars unit. I had to use the cutter torch to get enough head in them too brace and it worked well.
@andywithers5925 жыл бұрын
Awesome. I'd wondered what became of this base plate after watching the earlier video where you made the pattern.
@R.E.HILL_5 жыл бұрын
Would have been nice to see a comparison between welding and brazing strength wise repairing cast iron... Probably not a huge difference...?
@zanechristenson3436 Жыл бұрын
Wouldn’t you normally want to just use maybe a 3/4 inch end mill and step over to your finally dimension? To avoid things like the harmonics that may be made worse by cutting on either side of the slot
@SuperAWaC5 жыл бұрын
on a braze that big i'd have one or two helpers with torches keeping heat on the part
@cojones85185 жыл бұрын
That left-hander loved to squeal. Had my teeth on edge. LOL
@Eluderatnight
5 жыл бұрын
Pretty sure that was a production carbide cutter built for speed. Needed higher feed rate.
@abdulghanibinothman5 жыл бұрын
nice good for shaving piston head
@osgeld5 жыл бұрын
Keith's brazing speech is a bit like norm's safety glasses speech hehe
@80564432325 жыл бұрын
Have you ever lost a camera to heat while trying to get a chunk of Cast Iron hot enough to weld or braze? Sure seems like that would get everything hot for many yards around! Nice job as always Mr. Rucker!
@jrneff97735 жыл бұрын
mr rucker do you and or was able to get the brazing rod to flow at least to the bottom of the vee?? and when u flip it over and re heat it will the brazing rod bond to what you had laid down on the top my thought if I had any brass looking at me on the bottom I would've tried my best to melt it bond back to it on the back side minus it dripping out of your last weld. cant wait to see how you finished the project thank you sir
@altonriggs23525 жыл бұрын
One wonders how that massive piece got broken off...someone got his tool box and went down the road.
@wilsonlaidlaw4 жыл бұрын
Keith, what rods did you use for that job? I have to braze up a broken cast iron garden ornament for my wife. I do have SIF Silicon Bronze No.1 rods which is supposed to be suitable for both mild steel and cast iron. I will be using a Carbon Arc 180 Amp AC welding torch as I don't have gas but will pre-heat with a butane torch. The alternative would be to use some 2.5mm nickel/Fe cast iron welding rods but like you, my results with these have not been wonderful and have looked a bit messy. The cast iron is quite thin and I find it is easy to get holes with the Ni/Fe rods on an AC arc welder. From past experience, I find they work better on a DC welder, which again I don't have.
@Watchyn_Yarwood5 жыл бұрын
Just curious why you didn't layout the metal removal in 7:00 and band saw out the bulk of it instead of milling? Finish it out with your finishing end mill.
@samueltaylor4989
5 жыл бұрын
William Garrett probably because it’s easier drilling holes instead of bandsawing because you can’t turn the blade in metal you would have to make many straight cuts.
@paulcarre47195 жыл бұрын
Would have stuck with the roughing mill myself.
@chakathewolf5 жыл бұрын
You need a Do-All bandsaw!
@Devin82m4 жыл бұрын
Very cool videos, I dicovered you via ThisOldTony and Abom79. I'm curious why you didn't use oil or coolant for your cuts? I'm still learning, so didn't know if there was a specific reason why you shouldn't.
@dudleycornman16245 жыл бұрын
Might be nice to have a heat source to heat the table under the part?
@ohhpaul73645 жыл бұрын
Would leaving the welding blankets on top of the majority of the casting helped to hold heat in while you were brazing? Could you use something like a Kao-wool blanket to help hold the heat in? (Although, that stuff really needs to be coated with a rigidizer or something, so maybe Kaowool wrapped in a welding blanket.)
@tonyo934 жыл бұрын
Wouldn't have trouble keeping the heat in and not use so much "gas" in your bottles if your part was wrapped up in a welding blanket or insulation of some sort. What no post cooling hot box?
@dangodbout78185 жыл бұрын
Gas weld is the way to go.
@josephnorton19965 жыл бұрын
I have always brazed small parts that cant handle the welds, never did such a LARGE patch. There is a lot of brass there. When brazing large gaps like that, is the brazed joint weaker than the casted metal around it?
@siggyincr7447
5 жыл бұрын
Depends on what the base material is, grey iron or cast steel, but I'm guessing by the way it broke its just plain grey iron, in which case the brazing can actually be stronger than original.
@jimbeaver3426
5 жыл бұрын
I'd imagined the fit-up gap would've been closer to ¼" but then getting adequate heat on the bottom side would have required some challenging heating strategies compared to the wider gap and a rosebud tip from the top side. In retrospect, the much wider gap was the best choice for achieving proper heating.
@StevenAndrews5 жыл бұрын
Noob idea... What do you think about using some sort of insulating spacer under your part so your table isn't a big heat sink? Any value there?
@ryanwilson3424
5 жыл бұрын
ive done that before but the point of the welding table is that its pretty flat and very strong to limit how much the parts move so adding anything underneath would probably mess with that.
@grntitan1
5 жыл бұрын
Steven Andrews When at all possible, I braze and even silver solder on top of insulating fire bricks.
@athopi5 жыл бұрын
Wish you had more choo choo stuff...
@petergregory52865 жыл бұрын
That was quite a gap to span. Just hope you didn’t stick it to the table below. Regards
@steelcantuna4 жыл бұрын
So what does the foundry charge to make a piece like this after you send the pattern?????????
@chuckwin1005 жыл бұрын
I was wondering if it would not have been easier and faster to have the foundry recast the entire piece? Then its only a question of finish machining it.
@ohhpaul7364
5 жыл бұрын
I don't think he has or has access to a lathe large enough to machine the center pivot and ring on the base. He might but I am merely guessing.
@Blazer02LS
5 жыл бұрын
Don't think he has the equipment to do all the machining plus adding the degree scale on the base. Also would cost a lot of $$$$$ to cast that piece.
@lindsayfog5246
5 жыл бұрын
only take the resources of a large machine shop, pattern maker, foundry, one off tooling to cut an 18" circular tee slot in cast iron on a 28" lathe, pay everyone, 2 months later you got one that doesn't need a half hour brazing job sitting in the next state waiting to be driven into by a forklift and broken at the shipping depot
@jimsvideos72015 жыл бұрын
I do believe this counts for the rule that you don't really own something til you take it apart and put it back together.
Пікірлер: 172
Like my grandfather used to say. If we all liked the same thing . Everyone would be chasing your grandmother! Nice job!
I liked the one part of the video where you can see you turning the hand wheel on your x axis. For us that are not that experienced, I liked that we could see how fast (or slow) you were feeding the part into the cutter. I wish that all the machinists would show more of that in their videos, on the milling machines and on the lathes. Or all of their machines. Thanks for sharing, and nice job on the brazing.
I enjoyed your talk about why you gas braze, my opinion is there are hundreds of "right" ways to do a job, but the best way and usually the most successful way is the one you are most comfortable with.
Ive always found Torch Brazing to be the best, specially as you said Keeping a lot more heat into the Cast iron. My dear old dad showed me this more than 50 years ago on a Large Old Dawn Vice which i still have and still working like a Charm to this day. regards Dave from Australia
@morriewyatt6234
5 жыл бұрын
And as their old slogan used to go: "Make Dawn your only vice." Also from Australia.
@geoffmorgan6059
5 жыл бұрын
Brazing is the best way to go as long as the section is not really thick. An additional way to secure cast iron is with the "Metal-lok" or "Metal-lace" proprietary systems. For extra heavy sections (like the gear box on a Caterpillar D9). It works, but brazing is still used along with Lab Metal or Belzona, etc. You could pin this casting if you are concerned about bending loads, also helps with alignment. Of course you have to pin first. Good job!
@boldford
4 жыл бұрын
@@geoffmorgan6059 One of the problems with welding cast iron is the additional heat converts the iron into very brittle carbides. This is avoided with the lower temperature used in brazing.
Looks great Keith, sure glad I didnt have to cast the whole thing😁
@windyhillfoundry5940
5 жыл бұрын
@John Doe thankyou, I try my best
I completely agree with the brazing technique but I believe the preheating should extend to the entire casting.
Your brazing experience is valuable to novices like myself. It would great if you put together a video or two with all your tips and tricks on brazing. I have struggled with brazing but would like to master it. Great KZread channel by the way. Thanks for your efforts.
@tracylemme1375
5 жыл бұрын
I have found that most problems people have with brazing is the lack of heat. Preheat then preheat some more. Remember that the heat conducts to the entire casting. My dad said when choosing a tip, use one that is two sizes larger than you think you need. If it isn’t hot enough, you will fight the process until the very end when the casting finally becomes hot enough.
That is a big hunk of cast to preheat. I was surprised that the woodworker, in you, didn't scribe that joint in with dividers. Looking good though... can't wait for the finish.
@AffordBindEquipment
5 жыл бұрын
As a journeyman cabinetmaker, I agree. it could even be scribed from both sides to get the taper from the broken piece.
Great job brazing up the joint. I have been gas brazing cast iron parts for many years. The idea of an old oven to soak the whole part to 500 degrees over nite is what I always did on large cross section parts. I finish joint with filing surface vs. grinding prior to brazing, Was told years ago that grinding draws out graphite to the surface and inhibit good adhesion between parts. Great seeing old parts saved instead of sending to the dumpster.
Keith what a beautiful job on the repair glad I got to go back and watch this one!
Jon Kaase in the 2015 Vintage Engine Dyno Challenge quote, "I've got more money in the 10 pounds of special welding rod it took to modify the heads than I do the actual cost of these brand new heads." That's reason 1 for me to stay with gas brazing cast iron! Great job, as usual Keith!
What your shop needs is a good used oven, soaking large cast iron parts over night makes brazing them a lot easier and reduces heat warp as the entire piece is close to the same temperature. Ten years ago I picked one up from Habitat for $25.00, as a side benefit it can still cook a frozen pizza for lunch.
@dhc4ever
5 жыл бұрын
What sized oven did have in mind? I can see the point for small pieces say up to 15 to 20 inch, but the bit he's currently working on, not a hope, its got to weigh 300 lb. You are right about the pizza idea though. Cheers
@july8xx
5 жыл бұрын
@@dhc4ever It is a used Kenmore 30” wall oven, it came with a broken door handle and a burned out upper element, $25.00 from Habitat. You can get a 24” wide and 20” deep piece in it, longer if you take the door off and wrap the front with some Nomex blankets.
one of my favorite things to look at is freshly machined cast iron
👍👍👍Keith, I've seen you do several similar repairs, and every time you surprise me with the perfection, love your videos. best regards from belgium.👍👍👍
That was a braze job and a half. Came out great!
Great Job, I know nothing about what you do, maybe that's why I find it so interesting.
The more i get to observe you Brazing Cast iron the better. I recall from some years back that when i tried stick again after many years away from it, noticed I was more adept at it after many thousands of hours under the weld helmet working and watching that puddle during production Mig Welding. Exellent project planning. I kinda consider myself as part of my tools, that is like what I am more able with ME low on "Gas". One of the most enjoyable skills that I learned in the Weld dept. of a fab shop I worked at, was learning how to fix others mistakes. AND have it be a good part. I don't always say it but great effort and also a good product; Video and a good Part.
Looking good Keith. You did a nice job on the preparation, getting everything linded up and looking straight. By the time you clean the top up and get it painted nobody would ever know that it was broken. Looking forward to the next video. Thanks Andy
Most of the time I have no idea of what you are doing, your explanation helps a lot and I can see the craftsmanship you are having. That is what makes it interesting to watch your videos. My father (the lord has his soul) used to be a black smith maybe that's also why I like to watch your videos. Thank you for the upload Keith!
Great job, Keith!! I'm delighted with seeing this repair putting this piece back into useful service.
I've seen you braze cast iron before and I think your judgement on this job is spot on. I also like the idea of finding an old oven to preheat/bake pizza - has the added advantage of baking out any oils that might bugger up the brazing.
Hey Keith it's me mushroom hunter.. I think I confused a whole bunch of your viewers when I was running my mouth off about the rebuild.. I'm kind of hoping that you got it.. but just in case you didn't. I was just making a reference on how much I appreciate the master craftsmanship that it takes to be a skilled machinist, compared to what I do as a trim Carpenter.. I love your videos.. keep them up.. and I still hope to watch the rebuild enough times to comprehend the accuracy and dedication to precision that it requires to do the project you're doing.. most people cannot even comprehend 1/64 of a piece of paper.,... good on your brother!! cheers!!
The old adage of 'Grinders and paint...etc' never fails to apply does it! I hardly need to say it, but simply *excellent* work Keith! How you could get that rough casting so well matched to the broken piece is simply beyond me. I would have messed that up in three hundred different ways. Many, many thanks as always for the video. I look forward to seeing the next section of the repair.
Love what you are doing and because I learn so mutch.
It looks like a good cast and that was a good braze, like this repair. If you grind the weld a bit and then sandblast the whole part, maybe it blend in good and hardly noticeble after painted.
Keith I agree whole hearted that flame brazing is the way to go on something that large and thick. I have been doing that sense I was 9 you ears old and have worked for a company where we repaired large mechanical press rams and knuckles etc! . We always flame brazed and I have never had a failure to my knowledge. Good choice. I have also made a many repair using Ni - Cad rods and others but you still have to maintain a good bit of heat so I am confident you made the right choice.
Keith, do you have a profile gauge? It would make your life a lot easier for matching up parts like that. You set the profile of the existing part in your profile gauge, then put your new piece in place until it contacts the existing part as you had it, measure how far your part sticks out along that outside straight edge, then locate your profile gauge to the correct dimension from your existing part edge and trace your profile gauge onto the new part for a perfect edge geometry. This is useful for all sorts of jobs, even tile floors and millwork.
@N1gel
Жыл бұрын
Or a pèncil and sheet of paper.
Gave me a flashback of when I was watching my father-in-law braze an Old International 101 combine variable speed pulley half to re-build and bore the pin holes it road on. He was sitting with the pulley in a stump mounted vise, somewhat between his knees. A hot molten bead ran out and down the slope of the pulley and right in his half open laced boot. Big 6'-6" 280 pound man pulled that boot off tearing right out of the leather. Had went all the way to the sole of the boot and cauterized the wound on the arch of his foot. Last time I seen him braze anything.
At the end of the day its your job so you do it how you see fit. 😊 I love the videos having been an electrical / TV engineer this me a different sort of engineering to learn.
Nice job Keith! I've brazed a lot of exhaust and intake manifolds, and I've never had one fail!
G'day Keith always great to watch you perform tried and proved methods. Hand made patterns to flame tip brazing. Like they say when you're on a good thing stick to it.
Love it. Thanks for doing it on video. I look forward to the second episode.
Thanks for coming back to this, I was thinking I missed a video
Didn’t we see a video of you standing next to a 20” DoAll Band Saw a few months ago??? That would have cut that down to size with no trips to the museum! I love your videos!! Can’t wait to see it all together!
You are half way there! It looks like a very proper repair to me.
That's a pretty massive part to braze. Thanks for sharing. Look forward to seeing it finished and set up.
Great job 👍
Years ago I had an "interesting" brazing project. Somebody in shipping knocked a scale off the table and the cast iron base shattered! Wasn't critical to the operation of the scale more to cover up the inner workings. 1/4" thick or so. All these triangular pieces had to go back together like a jigsaw puzzle (and that took a while). Beveled the mating edges and started brazing. The tricky part was working in different areas so the heat from where I was working didn't melt the other brazed joints. Did one per day and let it cool overnight, then did one FAR away the next day. Got about halfway through and got laid off so I don't know if anyone ever finished it... :(
Thanks, Keith.
Yey, the table is getting fixed. Been waiting for this one so i can soak up some knowledge. Have a few repairs myself, and i've been chickening out of them for a reason or another.
@southjerseysound7340
5 жыл бұрын
I don't know what you need to fix but take a look at lock n stitch. Since using it I was amazed.
Those deep cuts had me on the edge of my seat, I was ready for a broken end mill or clamp slippage.
@boldford
4 жыл бұрын
Made my bum clench too.
I agree brazing is the best , welding in opinion allows for air and water migration if not solid thruout. And ive been around longer then most on here preaching the welding. Tig may be really good with the bronze filler rod from my perspective it should flow in to the pores of the metal like brazing rod with flux, borax.
I’m alright with doing what you’re comfortable with. I had no experience and when I learned to weld cast iron. But I have also seen some brazing repairs hold the test of time. You were spot on with your assessment. Thanks for the video, like to see what’s left up your sleeve
If you have a veary large piece to Braze for added strength drill and tap studs at different angles in the gruves use Borax flux generiously and use plenty preheat burners on the bottom castings 🙌🔥
Great job Keith thanks for sharing 👍
Brazing is the way to fix cast iron, I’ve asked old press operators when the press they have spent their life on was repaired, the answer is always “before I got here” !
Beautiful job! Thanks for the video.
That harmonic. Wow
Great video as always. The only thing I would have done differently is I would have preheated the parts on the charcoal grill to about 350. Saves a lot of gas. Kent
@jameshatfield7634
5 жыл бұрын
I agree to that,more even heat.
@WoodNMetalWorkshop
5 жыл бұрын
@@jameshatfield7634 That too. I used to have an old electric oven in the shop for preheating parts and small powder coating jobs, it was nice to be able to take a freshly brazed part and toss it back in the oven for a controlled cool down as well. I may have to check Craigs list for another one.
Excellent brazing job!
Been waiting a long time to see how this turns out looks great so far Keith
Very interesting video thanks for sharing.
GREAT JOB KEITH...
I have a cross slide I need to fill in where its pulled up and busting. Missing chunks. I'm thinking this is great inspiration to proceed with the repairs.. thanks Keith.
That is a massive piece of metal to braze. I can see how you would have trouble keeping enough heat in it.
Nicely done. I wondered like several others why you didn't try and get heat into more of the part before you began brazing, but I guess you just had to be sure you could keep the repair area hot enough while brazing and the rosebud supplied enough heat? Thanks for the video.
Hi Keith Very nice piece of work and quite enjoyable to watch while you expended all the effort. Sure the base will serve you well for many, many more years. The complexity and quality of those vintage machine casting is something I always find impressive. :-)
I know this is an old video but I do alot of old farm equipment repair which consists of a lot of cast repair we don't have time most of the time to heat and weld and reheat and pack cast to do so called proper cast repair and most of the time the piece is still on the tractor or implement. If it's a no load item I always braze it I have cast things I brazed 30 some years ago still holding up still doing their original job, If the part is something with a load or is in contact with ground such as tillage implements I weld them back together with 308 stainless rod bonds cast nicely and wears good in the abrasive dirt I've never once have had a repeat repair on cast parts welded with stainless many of the old timers did it and many of their repairs are still holding strong see them everyday just about. You'll of course have your keyboard warriors tell you brazing or welding cast with stainless is wrong it will never hold it's weak and so on because they have never done it or they can't weld period or they never cleaned their parts properly or someone told them it's wrong and doesn't work. I have a Cat D7 dozer that was abused it's whole life in a rock quarry that machine is pretty much all brass and stainless with all it's welds and cracks that were repaired over it's life but the machine at 73 years old will still go out and push dirt all day long like it was built to do.
No school like the old school 😁. There's a little too much tig fluff out there anyways imho 😊. Nice work, Keith.
@boldford
4 жыл бұрын
The heat is too localised with an arc.
Couple of comments from one old school maintenance man to another: If brazing gets the job done for the intended purpose, why weld?!? It's kinda like going to prom in high school. If you can take your girl in a ragged out AMC Hornet and get as much "action" either way, why rent a limo? Yeah, I drove a Hornet in high school. It worked just fine for me... As for torch versus TIG brazing on cast iron of parts that big; Torch all the way. With cast iron you HAVE to spread the heat before you braze or weld. the important thing is to keep the heat differential down between the part and the weld/braze area. You kinda want to 'feather' it out. Unnecessarily changing tools to get a job done is frowned upon in the real world. It's also important to evenly cool the piece down after brazing, and passing the rosebud over it every once in a while while it cools helps to relieve any stress imparted by the brazing. The blanket helps a lot, too. Interesting trick taught to me by my mentor in industrial maintenance is what I call the "Rosebud Trick". If you take a rosebud oxy acetylene tip and light it on just acetylene, you can coat a part in pure carbon. Interestingly enough, once that part gets to about 400 degrees F, the carbon on it wants to make CO2 with the ambient oxygen in the air. Even more interesting is that 400F is about the temp you kinda want to pre heat cast iron and aluminum to, before brazing or welding. Long story short, that torch in your hand is literally a 'multi tool' if wielded right. It is not only a pre heater, it is also a pretty precise temp measuring device, and it is the tool you can use to weld/braze. Side note: If you want to case harden some steel, you don't need to buy Carbonite case hardening powder. Just use a rosebud and switch the oxygen off to add some elemental carbon, then on to raise the temp. Rinse and repeat. It's slower in a sense, but quicker over all. You're not sprinkling powder or dipping parts in a can. You're just turning a valve every once in a while. Oxy acetylene torch sets are golden tear drops of God's sweet love to old school maintenance guys. Molon Labe! Come and pry my Oxy Acetylene kit from my glove covered hands!
If only more of us would get things repaired instead of throwing everything out.
@ohammouda
5 жыл бұрын
@Barry Manilowa If you're sick, go to a fucking doctor don't complain here.
@organbuilder272
4 жыл бұрын
@Barry Manilowa Barry, That is really uncalled for. If you are a fan of Keith's and other similar sites, I think you understand how Landrew feel. He's not sanctamonious, he is making an honest comment. Okay...
@bettytherussiantortoise2808
4 жыл бұрын
Barry Manilowa stop acting like a chromosome deficient pile of crap and how about go crawl back under the rock you crawled out from
My GO to is also brazing when I can put the preheat into the c
@edwardkawecki8101
5 жыл бұрын
My go-to is also brazing when I can safely put the preheat and the heat into the cast iron part. Second is a nickel or cast iron stick rod if looks don't matter, but I have had a lot of great repairs on cast using LH 7018 welding in very short runs and peening the heck out of them immediately and skipping around. Weld matches very good and keeps the heat low enough not to distort anything. Always worked best for me when having to weld mild steel to ductile material like manhole risers for asphalt road paving. Nice video Keith, thanks.
enjoyed...great discussion/build...
Those were some big cuts. Thanks for sharing Keith, Cheers
Nice work!
I'm the same way, my goto method is brazing if possible. I am much better at brazing than welding.
@southjerseysound7340
5 жыл бұрын
I used to be the same until I used lock n stitch. Now it's my go to although might've brazed this too.
Good job!!!
13:00 RIP headphone users
THANK YOU...for sharing. Enjoyed.
Nice one. My choice of brazing method as well. Des.
Great Job on saving a old piece of great equipment !!!!!!
waited up for this nice
great job, and enjoyed
The company I work for has motors with inter graded gear boxes. That have circular cutting blade on them as they run on a track and have a hard stop they brake the ears off . This was due to the wrong size blots to hold them down I found out later when I took it apart I was asked to look and see what was wrong I saw that the ears had broken off and told the lead Hand and he said to shut the machine down Untill we get a unit. I told him I can fix it give me two hours and we will be running .As the gearboxes are cast steel I brazen the ears Back on and we where running. Only to find out their where three other units all the same , so I fixed them all that was their and saved the company $ 1500.00 dollars unit. I had to use the cutter torch to get enough head in them too brace and it worked well.
Awesome. I'd wondered what became of this base plate after watching the earlier video where you made the pattern.
Would have been nice to see a comparison between welding and brazing strength wise repairing cast iron... Probably not a huge difference...?
Wouldn’t you normally want to just use maybe a 3/4 inch end mill and step over to your finally dimension? To avoid things like the harmonics that may be made worse by cutting on either side of the slot
on a braze that big i'd have one or two helpers with torches keeping heat on the part
That left-hander loved to squeal. Had my teeth on edge. LOL
@Eluderatnight
5 жыл бұрын
Pretty sure that was a production carbide cutter built for speed. Needed higher feed rate.
nice good for shaving piston head
Keith's brazing speech is a bit like norm's safety glasses speech hehe
Have you ever lost a camera to heat while trying to get a chunk of Cast Iron hot enough to weld or braze? Sure seems like that would get everything hot for many yards around! Nice job as always Mr. Rucker!
mr rucker do you and or was able to get the brazing rod to flow at least to the bottom of the vee?? and when u flip it over and re heat it will the brazing rod bond to what you had laid down on the top my thought if I had any brass looking at me on the bottom I would've tried my best to melt it bond back to it on the back side minus it dripping out of your last weld. cant wait to see how you finished the project thank you sir
One wonders how that massive piece got broken off...someone got his tool box and went down the road.
Keith, what rods did you use for that job? I have to braze up a broken cast iron garden ornament for my wife. I do have SIF Silicon Bronze No.1 rods which is supposed to be suitable for both mild steel and cast iron. I will be using a Carbon Arc 180 Amp AC welding torch as I don't have gas but will pre-heat with a butane torch. The alternative would be to use some 2.5mm nickel/Fe cast iron welding rods but like you, my results with these have not been wonderful and have looked a bit messy. The cast iron is quite thin and I find it is easy to get holes with the Ni/Fe rods on an AC arc welder. From past experience, I find they work better on a DC welder, which again I don't have.
Just curious why you didn't layout the metal removal in 7:00 and band saw out the bulk of it instead of milling? Finish it out with your finishing end mill.
@samueltaylor4989
5 жыл бұрын
William Garrett probably because it’s easier drilling holes instead of bandsawing because you can’t turn the blade in metal you would have to make many straight cuts.
Would have stuck with the roughing mill myself.
You need a Do-All bandsaw!
Very cool videos, I dicovered you via ThisOldTony and Abom79. I'm curious why you didn't use oil or coolant for your cuts? I'm still learning, so didn't know if there was a specific reason why you shouldn't.
Might be nice to have a heat source to heat the table under the part?
Would leaving the welding blankets on top of the majority of the casting helped to hold heat in while you were brazing? Could you use something like a Kao-wool blanket to help hold the heat in? (Although, that stuff really needs to be coated with a rigidizer or something, so maybe Kaowool wrapped in a welding blanket.)
Wouldn't have trouble keeping the heat in and not use so much "gas" in your bottles if your part was wrapped up in a welding blanket or insulation of some sort. What no post cooling hot box?
Gas weld is the way to go.
I have always brazed small parts that cant handle the welds, never did such a LARGE patch. There is a lot of brass there. When brazing large gaps like that, is the brazed joint weaker than the casted metal around it?
@siggyincr7447
5 жыл бұрын
Depends on what the base material is, grey iron or cast steel, but I'm guessing by the way it broke its just plain grey iron, in which case the brazing can actually be stronger than original.
@jimbeaver3426
5 жыл бұрын
I'd imagined the fit-up gap would've been closer to ¼" but then getting adequate heat on the bottom side would have required some challenging heating strategies compared to the wider gap and a rosebud tip from the top side. In retrospect, the much wider gap was the best choice for achieving proper heating.
Noob idea... What do you think about using some sort of insulating spacer under your part so your table isn't a big heat sink? Any value there?
@ryanwilson3424
5 жыл бұрын
ive done that before but the point of the welding table is that its pretty flat and very strong to limit how much the parts move so adding anything underneath would probably mess with that.
@grntitan1
5 жыл бұрын
Steven Andrews When at all possible, I braze and even silver solder on top of insulating fire bricks.
Wish you had more choo choo stuff...
That was quite a gap to span. Just hope you didn’t stick it to the table below. Regards
So what does the foundry charge to make a piece like this after you send the pattern?????????
I was wondering if it would not have been easier and faster to have the foundry recast the entire piece? Then its only a question of finish machining it.
@ohhpaul7364
5 жыл бұрын
I don't think he has or has access to a lathe large enough to machine the center pivot and ring on the base. He might but I am merely guessing.
@Blazer02LS
5 жыл бұрын
Don't think he has the equipment to do all the machining plus adding the degree scale on the base. Also would cost a lot of $$$$$ to cast that piece.
@lindsayfog5246
5 жыл бұрын
only take the resources of a large machine shop, pattern maker, foundry, one off tooling to cut an 18" circular tee slot in cast iron on a 28" lathe, pay everyone, 2 months later you got one that doesn't need a half hour brazing job sitting in the next state waiting to be driven into by a forklift and broken at the shipping depot
I do believe this counts for the rule that you don't really own something til you take it apart and put it back together.