Challenging CRACKED Cast Iron Housing Repair! | Flame Spray Welding
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- Опубликовано: 5 июл 2024
- Can we fix this cracked cast iron transfer case housing!? This housing is off a Caterpillar 966K Wheel Loader, there are multiple cracks through the bolt holes into the housing so we’re going to have a go at repairing it! Repairing cast iron is always a challenge because of how ‘dirty’ and brittle the cast iron material is, and repairing a large and thin housing is one of the most challenging parts to try and repair. For the repair we will be using our preferred method of metal powder and jet flame spray gun with oxy acetylene. We also show the process of dye penetrant testing to show the cracks and grinding them out before using flame spray welding. Will this repair work or fail?!
In this video we are using:
- Dy-mark Flawchek dye penetrant system
- UTP Variobond flame spray gun
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Hey everyone 👋 We've unfortunately had delays getting seals to finish our Hitachi cylinder rebuild this week so we've got this cast iron job videoed instead! Hope you enjoy it 😄👍
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It is too a zoo!
Have a crackin' weekend guys. I'll see myself out.
Homie gave me a decent laugh with his box attack. It didn't stand a chance.
With cast iron that noise, once heard can never be forgotten. Bloody good effort though. Stuart from Sydenham Vic
@@isthatbikedieselmate That Crack was mad! I jumped in my chair when I heard it.
The fact that Kurtis is willing to have a failed project published just shows how professional and confident in his skills he is. Accepting ones own limits and not being afraid to state them really shows character. Also not charging the customer! No wonder kurtis has so much to do, good on you!
This^^^
I've worked with cast a few times and my record isn't great. A big part like this? Doomed to fail, but a great learning experience. Hopefully the customer offered to at least cover the materials cost but I'm sure the honesty and attempt will pay dividends later
Dude...not too long ago I had a case from a pneumatic jack hammer...NO MATTER WHAT I DID... as per recommendation...DID NOT MATTER!!!! Cracks persisted and though it was considered a loss anyways it was surely lost after. Huge bummer, I didn't learn much because my boss knew less than me. Huge bummer, I really wanted to get it done. Either I missed something or did something wrong consistently 😂.
Though watching all the nickel ball up during gouge was interesting. I feel like that was indicative of something crucial. Oh well...I'm a librarian now😂😂😂😂
Exactly 💯
Dude. Spoilers(
yeeep just shows you how good he is, what a legend !!!
The slow character development of Kurtis turning into a Disney princess with the birds is priceless. Homeless getting better and better wrecking packages is hilarious. I commend you for posting a failed repair, but often times our failures teach us more than our successes, Cheers to all three of you. Much love.
He’ll be singing next
@@frankblack1481 lol! I’m waiting for the birds to match his whistle. But you gotta admit, he is magical.
I'd pay good money to watch Kurtis the Musical@@frankblack1481
the dog opening he packages is hilarious. he opens cardboard better than i do with a knife.
Homie will save the failed cast iron. I have full confidence.
As a foundry engineer who works with ductile iron all the time, CAT is notorious for isolated thick sections in the middle of thin sections geometries… this creates a lot of residual stresses in the solidification and cooling process. Drill holes to add stress concentrations and now you have a casting destined for failure! As always, the CEE content is great!
great to see this insight, the large final crack was exactly like you said, he colder casting could not handle the expansion of the thick heated section with the ring
And maybe too much bearing load? The crack is on the outside, so the force was pushing outward. And the bolt hole cracks feel more like fatigue than impact
You´d need to engineer some casting forms that can be heated in respective areas then. 🤷♂
I suspect tho that either those impurities or inclusions were on the upper end of the "go" spectrum in roentgen or it has been run with almost no oil and been hot.
QUESTION: If that housing was brought up to nearly cherry red and THEN welded or spraywelded and then put back into an oven and slowly brought down over time and then held at like 400° for a time and then just allowed to slowly cool or buried in sand and allowed to cool...would it crack?
@@willybones3890 it wouldn’t crack, but it would anneal and settle. And the holes would all settle into happy positions. It would need to be fully machines again :o(
I am a one man auto repair shop in Indiana. I've had your videos playing the shop last few days. While your workmanship is top tier and integrity is first class, I'm most impressed by your time management! You're never rushed, never stressed, and I have no idea how that's possible!! Please tell me your secret! Also, I think an "unboxing" series from homeless would take over the internet.
Er ist selbstständig und hat keinen Chef der ihm auf die Nerfen geht.Er ist sein eigener Chef.
A large, complex casting like this, which has had multiple machining operations, been stressed through use and developed cracks without any obvious reason was always likely to be a lost cause. I hope your customer watches this and realises the skill and effort you put in to try and achieve a good outcome.
Couldn’t have said it any better myself 👍🏼👍🏼👍🏼👍🏼
Wonder if it was a flawed casting in the first place if there were jo obvious signs of what caused the initial cracks ?
@@mrb.5610 there's always a chance, though Cat typically have good quality castings from what I've seen, you almost never get this kind of thing without any other damage or obvious issues. Not a job I'd want to take on regardless, cast iron repairs are a bloody tough thing to get right, especially something as big and complex as this
@@mrb.5610 I was wondering that also. It just seems strange no visual damage yet cracking occurring? And then all the cracking happening when trying to repair, something fishy going on there…
@@GeorgeLittle-ft2yx Residual stress from whatever impact cause those initial cracks. Either the shaft got clobbered, or the one wheel was suddenly bound up with a large rock or ditch, and the shock through the transmission caused the initial cracks, but also left a lot of strain bound up in the bulk of the thin side. Just needed enough heat to stress past the yield point, causing the crack, or one of them spread from the heat input to the point it hit the stressed material, which could have been there from when originally cast. About the only way to have prevented it would have been to put the entire casting into an oven, and taken it up to 800C for 24 hours, then let it cool at a controlled rate of around 20C per hour to room temperature, which would have released most of the stress, and likely shown the casting was badly distorted as well.
Big oven, and also inert argon atmosphere as well. Would suggest as well the new casting is bought along with a new output shaft, as that likely also has some buried cracks in it, which probably will show up, with eddy current testing or gamma inspection. Might be cheaper to buy the entire unit ready built, as that gives a warranty on the part.
In the shipyard they had large cast part on a large bed of coal with fireproof blankets on top. They repair it right in the burning coal. After that still under the blankets. They slowly let the coal to burn all up and let it start to cool. This was not a one day job.
Full marks on trying to fix a massive cast iron part.
Or they fully cover the pieces in sand. But in any case these shops still cannot save every piece.
@@danielrauer5864
So true. Some cast have so much crap it the steel. It make you wonder if they ever use flux to remove the trash
good try dont thin you had much chance very poor metal to even crack like that.
I guess that's the way the other guy who is so busy does it, by heating and cooling the entire piece over time. Using an oven that holds the entire piece and reheating as necessary. Kurtis isn't setup for it and the result shows. A most interesting video.
My thoughts too!
As always, solid work. You can't save everything, but we sure do like to try. I worked on the railroad here in the U.S. as a Carman (train car repair). All the couplers are cast and part of our job was to look for cracks in these components. When we had to perform a repair we had a similar approach to what you did Kurtis with 1 or 2 notable changes. We had temp sticks that we could touch to the part, and when they melted, we knew the part was at temp. We also periodically rechecked to make sure no portion was cooling down too fast during the repair. I think the gas burners are a good idea. However, I think had you spaced them further from the repair area to heat more of the part, it probably would have helped. One more thing we did was to cover the part in very thick welding blankets when we were done, to insulate the part from cooling too fast. I'm sure you've already learned the lessons that come with failed repairs, but that's half the fun, in my opinion. I hope you find this constructive and I still feel like you did good work. Cheers from the Ohio/Michigan line
I have seen and HEARD when those couplers crack. Sounds like a pistol!
The way i see it is for this dimensions, you need to put the entire cast in a oven to bring all of it to the desired temperature. Come out the oven wrap it up in blankets to preserve temp as mush as possible and repair the cracks. Obviously to work on this amount of steel mass, you need to wear a suit protection, and in final put it back in the oven, equalizing temperature and then do a controlled cooling down. I think it requires special installations. Kurtis is a brave man, a honest one, good for him to be that way with is costumer. This was a great experience. He's young and will continue to gain experience and already has the correct approach to keep growing. Great video.
Can the casing be saved with a new steel insert brazed into the iron?
I think those temp indicatores are called pyrometric cones he in USA
You actully can save it all just follow proper welding procedure time and patience we fix it all
For me the least important thing was the impossibility of the concert. For me, the honesty and transparency demonstrated are valuable and inspiring. Thanks.
Kurtis thanks for showing us things that go wrong. The guy that taught me to weld said that it’s only by understanding why something went wrong that you can learn how to do it right. A mantra I still use today.
You both work so hard on getting things right within your relative skill sets that makes every episode a joy to watch, you and Karen deserve every success.
Homey’s contributions are also priceless.😂
He wouldn't if there was no Homey time in it
At the beginning of this video I told my girlfriend this guy is nuts for even attempting what he's about to do. I'm sorry for laughing when I heard the crack but I realized that I was right. That is just way too much damage cast-iron to successfully fix. At least with my welding experience. I've been a welder for 18 years and was rooting for you. I was hoping I could learn something from this. What I learned is that cast iron is just as difficult for you as it is for me.
Saludos hermano espero te encuentres bien, quería preguntarte si en tu experiencia de 18 años que hubieras hecho tu y que hizo el mal que se pudo haber evitado esa falla tan catastrófica de la carcasa
@@catpartsforyouokay, so to make it not sound like a brag, share some wisdom: do you think any mistakes were made here? Is it a simple case of just not having the right equipment? Any tips for others, or Kurtis in how to have more success in the future? Any thoughts on whether impurities in the casting may have contributed to the problems? Would you have used a puddle/powder torch? Or a different method?
@@catpartsforyou I would think that the freight alone would cost more than a new part locally, if they were to send it from Australia to US and back for repairs.
@@davidbastow5629just guessing but I’d say the main problem was uneven heating. Kurtis heated it up but h wasn’t able to really make sure it was all the same temperature. And when he started welding that part got much harder then the rest and it started to crack, or make cracks that were already there get worse.
@@catpartsforyou it’s all well and good telling the world how easy a repair this would be for you but for those with less wisdom than yourself, please enlighten us to what you would have done differently. Otherwise any Tom Dick or Harry could say that they would have fixed it successfully.
I’m so impressed how deep and broad Kurtis skills are. He’s a top notch boiler maker, machinist, sculptor etc etc. Great talent and hats off to those who taught him him his skills.
And his materials knowledge and domain knowledge. Brilliant.
Sometimes a bad casting is just a bad casting no matter how much love you put into it. Great video I much enjoyed it
@@dekus80 i hear what youre saying but remember the casting was already damaged and stressed before he started working on it. Not that we’ll ever know the cause of the original failure but that definitely plays a large part in it!
Really seems to just have been a bad casting from the start. From my limited knowledge casting is kinda dice roll thing. Maybe that one cooled to quickly from the factory. At least it didnt fail in use and take some expensive gearing with it.@@spudatbattleaxe
What I love about your channel is that you aren't only showing the "best case scenarios" of everything, you show all the low points as well. The fact that you didn't charge for a repair that didn't work out speaks tremendously for your character and that you never want to compromise on what your work means to your customers. Nothing but respect to Kurtis, Karen and everyone's favorite safety officer.
Unfortunately, the world is full of hungry 'operators'
In litigious US of A, some might sue if they thought they'd MAKE a buck
That the customer accepted the risk speaks of both their characters...👍
Here in the US of A we are full of money grubbers, too many people have no integrity anymore. It’s a breath of fresh air to deal with people who have integrity. Look a man in the eye and shake his hand and that should be golden, but unfortunately nowadays often times when you turn and walk away you get a knife in your back.
You my friend are a perfect example of integrity, that’s why I enjoy watching your content, cheers to you and your wonderful lady and of course the side kick.
The most important thing was that you clearly talked it through with your customer regarding expectations before you started!!
I know you didn't charge, but I hope your customer takes care of you of you some for the efforts knowing it might not work. Only fair.
Cast iron is a pain no matter. Not many out there would show a failed repair. Props to you Kurtis. You told the customer what may happen. It happened and showed the internet how things can go pear shaped.
100% a decent, honest dude. And WE all learnt how hard it is to repair!!!
I know welders who have welded engine blocks with NIRod with preheat and post heat that failed and also just quickly welded without cleaning or any prep and some just work out and others don't.
I think more than 50% of what we have learned in life came from our fails rather than our wins.......when I am sober tmrw not sure that will be as profound.?..lol 3:13 a.m. in my man cave in PA USA....lol
100% agree! I only found this channel a few days ago and was very impressed with Kurtis's work ethics from the very first video i watched. Even with my limited engineering background i learned VERY early on that CI is a right royal b's****d to deal with( unlike Kurtis i actually like working with CI on my lathe and mill LOL! ) I would hazard a guess that this particular casting came with unwanted stresses in it ,straight from the foundry, i reckon there was a problem with the cooling of the casting right after it was 'de-moulded'@@tbrowniscool
Just another reason why so many people follow every episode of CEE Australia. Thank you Kurtis for putting that episode on here. The way you explain every detail as you work is amazing.
Kurtis’ reply to no coffee was too funny. I love watching these videos as all the machining and such has really peaked my interest, add in the birds and the doggy it’s just a good watch every time. 👍🏽👍🏽
As an engineer this kind of content, that shows you a failure of a project is so valuable and is the closest thing you can learn that is closest to actual experience. Thank you. ❤
We made thousands of gearboxes over the years and thankfully never suffered too much from cracking. One type was prone to cracks so we redesigned the area and changed to SG iron, problem solved. Rarely have I seen breaks like yours, but there were one or two that were caused by rapid stopping and as the gearbox was under load the area around the output shaft would exhibit cracks more often through the dowel pin location holes and also on a few of the bolt holes. Very interesting post which exhibited the problems that can arise with cast iron repairs. Thanks for posting Kurtis, Karen & Homey 👍
Hi Curtis I would recommend that you try Eutectic electrodes for cast iron. Cast iron electrides are usually 100% nickel or a Ni/Fe blend. They are a bit expensive but are good quality. The advantage of using an electric arc process over oxy is that there is much less heat involved. While you have the broken casting it may be a good learning expereience to trial some electrode repairs. I have persponally used (sucessfully) Eutectic electrodes to repair a cast iron frame on a tractor about 48 yrears ago. So Eutectic has been around for a while. Also progressive heating in small steps then wrapping in an insulating blenket may help to give a slow uniform temperature rise especially with a large 3 dimensional complicated casting.. Also wrapping in a blanket after doing the work will ensure a slow cool. Differential expansion and contraction is the killer with cast iron. Even with an electrode repair, preheating the job is still requird. Cheers.
Good effort Curtis,
Too bad the casting cracked, “there’s cast iron for ya.
May I suggest that you take the Barbecue plan to the next level.
You may want to heat the whole housing with charcoal a “bonfire” to heat the whole casting so the process may have a higher probability of success.
The cooldown is also easier to manage as you can allow the the heat to die down slowly.
It will be a hot workplace though!
Not sure any amount of skill could have saved this casing, kudos to CEE for even attempting it and showing us the results, failure is a learning process just as important as success👍
ive been with the channel since the beginning. What strikes me is the willingness to admit defeat in certain instances and in doing so make it a victory for the channel. The explanations, the work, the videography, the editing, the comic relief, all of it come together to make the channel truly the special thing it is. Why there are not a couple of million subs defies logic. Certainly deserving more as it is one of the best channels on youtube. Cheers from Texas.........
hey mate we know you've been here for the long haul and really appreciate it!!
Hey up mate I think this is probably your best video yet,really enjoyed it, has the 40 year man made a comment on this would be interesting, anyway love the honesty and all the best to you three
In due time Kurtis will have millions of subs. His channel is growing at a good pace. Many of his videos should be shown in technical schools. We all learn so much from watching his content. I still can’t fathom how Kurtis has so much knowledge at his age.
WOW ! You are human.. We all try and fail sometimes.. If you haven't failed , you are not trying the hard things in life.. Great vid Amigo.
This is actually the best video to demonstrate the problems with welding cast iron that I've ever seen. It's highly educational and should be shown in its entireity to EVERY welding class.
Nothing wrong with failure as long as you learn something from the experience . In my opinion Curtis has an overwhelming amount of knowledge and experience in his craft ,work ethic and passion to do the job correctly and methodically. Thank you Kaeren for your great contribution and skill as a videographer to bring these valuable work experiences to your followers and Curtis for sharing his vast knowledge .
Showed this video to a mate of mine that works in the on site workshop. We had exactly the same issue with one of our 980's. He said that it apparently is a material quality issue on some Cat machines from a few years ago. I have no idea if that is the case, but he's been in the business for over 45 years and usually knows what he's talking about.
It certainly looks suspiciously like there is a fundamental problem with the entire casting.
Hey mate thanks for the comment, it could very well be 👍
It shows how honest he is. I really like watching him and his wife’s videos. Greetings from the Netherlands ❤
I really appreciate you showing that even with careful planning and good work, a repair may still fail and that it's super important to notify the customer of the risks. Love your channel.
I love that you show failed attempts too😊
Bravo to whomever cleaned it before sending it to you!
There was Water/Fluid in the crack, so most likely they cleaned it in a big heating pool with cleaning solution, soaked that fu**er over night before inspection
Yes, they should get some credit, because that part was bound to be absolutely filthy and yet it arrived in presentable condition.
And props to their maintenance guys for spotting those cracks when they were still so small, there'd be a good bit of damage if the casting had broken fully while in use
@@helplmchoking oil leak they were trying to fix was a smoking gun. But still, your right.
Steam blast cabinet similar to what they clean engine blocks in
Kurtis, you may not see this comment as this is an old thread but from what you said about no damage from the equipment itself it is likely it was a bad casting in the first place. It wouldn't be the first time something like this has happened because of the casting like you said in the video cast iron is inherently dirty. Another thing is it could have been installed improperly somebody may not have tightened it down in the right sequence or didn't torque it properly. Glad to see you still uploaded the failed repair video it shows your character.
Im impressed with people that put failures out for everyone to see and learn from. Its better for us to see the problems before we go spend $1000s in matls, time and energy to just ruin someone's equipment. And more respect for not charging them. There are a lot of shops that would still charge them for it, at least here in the states. I'm a subscriber for good.
WoW!! Not everything can go to plan and i for one appreciate that you uploaded this video due to the nature of how the end result showed itself. I for one got more insight to just how difficult cast iron can be to work on. Loved the video.
There is a back story to that casting ... Cast Iron tough to work on, but that case has a LOT of stress in it to continue developing new cracks like that. Honestly not sure it would have been repairable, regardless of who was attempting it.
And .. Puddle Guns are so much fun!
Thanks for sharing 🇨🇦
Yea, I doubt that one went through a proper normalizing (stress relieving heat treat) when it was cast. There was a huge amount of residual stress in that casting. Even if it hadn't cracked while he repaired it my bet is it would have continued to crack in the future.
I hate cast! The crystalline structure and the junk in the metal is such a pain to work with. All you have to do is grab a piece of cast and light up your tig torch and watch the garbage come up and float in the pool of molten metal.
Yes... I too suspect that casting was junk from day one. It cracked for no apparent reason. So is as full of stress and and maybe inclusions. I hope CAT did not have that cast in the states, its embarrassing. Should have been warranted out early on.
The stress was not there to start with (that's what cast means), but high heat in isolated places was never going to work. Not to mention high nickel in spots. Well now we know.
_"that case has a LOT of stress in it to continue developing new cracks like that"_ - my thought exactly. Firstly, "original" cracks developing for no apparent reasons, right at stress rising/ concentrating points (bolt holes around a large openings), from (presumably) regular work induced stresses and vibrations - like, "whisky tango foxtrot?" - and then the enormous cracks developing while the case cooled down... This case must have been a piece of junk from the day it left the foundry, just waiting to show its true colours. The bottom crack, the last one, wasn't in any way connected to those at bolt holes, yet it developed "just like that", and not when heating the case, but during the cooling. I remember watching Keith Rucker building up, by spray welding, damaged ways in a steam loco stoker (made of cast iron, obviously) and it was all smooth, easy-peasy even though the walls of that stoker seem to be much thicker. (You can watch it here, "Steam Locomotive Stoker Engine Restoration - Part 7: Spray Weld Buildup of Cross Head Slides", ruclips.net/video/5kcTeyw2As0/видео.html.)
To all you people saying this is a failure it is not. This is a learning opportunity for these two. When you say failure you immediately admit defeat and do not ever do that just learning the few mistakes you made. Like i said the few mistakes once again I would love to work with you because you learn and remember from every job you do.
It's the temperature differential. The entire part needs to be evenly cherry red. A great investment should be a bigass kiln. Place the entire thing in the kiln/oven, spray weld with a larger orifice, higher material volume, and place back in the kiln for reheat.
Every cast piece I welded worked a bit better when the whole part was hot AF.
You may be able to save the part if you mill out the face to the edges, place the new plate on top and with a bevel. weld it on in sections while the whole housing is hot AF, reheat and then mill/bore out the features that face needs after the cool down. The plate will need to be hot too so there's no major tension when it cools.
I fixed a few cast iron outdoor tables, they had this basket weave pattern and it would dissipate heat fast and would explode in a star pattern when the outside perimeter would cool faster and shrink while the inside hub would expand with the weld and destroy the whole thing.
A true master craftsman does exactly what you did at the beginning of this video. Always give the nod to the guy that's better than you. Then to promote a GoFund me for a competitor. Pure class.
Matty is a good friend of theirs.
So mr Curtis, after episoes of watching you, I decide to leave my comment straight from Poland, Europe!
You are true master of your job, and well - episodes like that, are absolutely great, great example of your honestly and professionalism.
Its true pleasure to watch your Video guys, I can really learn a lot, see a lot of new methods, way of approach etc.
Best Regards, Adam!
So much respect (the deepest definition of that word) for Kurtis showing that things don’t always work out the way you planned and how to handle them like a true professional. All you can do is try.
Advising clients and honoring your work is a true sign of a pro. You are a honorable man Kurtis. Professional and fair.
Even with a massive bust like that, it wasn't exactly a failure. You called it correctly going in, you did everything possible to obviate all the problems, but in the end it was cast iron that simply overwhelmed you. A great shame because you deserved success with all the prep and, at least, your customer can see precisely what happened and when. They can't accuse you of not trying!
Great vlog, as usual and your wild bird audience seems to be getting bigger. You'd think all the noises, movements (and smells probably) would scare them off permanently, yet they keep coming back for the treats. Nice one.
Sometimes you're windshield, and sometimes you're the bug. Great work attempting that. Always enjoy your uploads.
Welding cast iron is hot, sweaty and stressful job. You usually get it because a replacement is bloody expensive or unobtainable. Welded quite a lot with oxy/acet and ferrite rod. As with electrode, fixing a lug or a straight across crack is fine, but come to welding a hole in the middle of something, it never ends well. And all that sweat and gas come to nothing. But we always seem to try again.
Thanks for all your cracking videos.
Brian from Lancashire England
Before even going through the video ...
You supporting a human going through a tough battle with cancer is absolutely AWESOME ...
Oh and by the way ... keep them videos coming ... 💪💪💪
Matty deserves it, and honestly feels like the least we could do for our good mate!
Lots of turbo cancers recent in Oz thanks to the eugenics pointy thing in arm
@@benwinter2420 You think thats bad ? Australia is huge i live in a small village in Croatia with barely 1100 people and 2 people from my family died of cancer, i know 5 neighbours that have it or had some type of cancer,and there is plenty of people in village that die or get sick.Worst thing is everyone is clueless whats causing it since we dont have big industry nearby or badly polluted air.
I am afraid i will have to run away or i might be next . . .but i dont have money to do it.
😊
👊😎
i am a software developper, but i think without computers, society will still be ok. but without machinists, we go back to 1700. big respect to you all out there. you make the world function.
Hallo Kurtis!
Wo hast Du all das gelernt?Du kannst jede Maschine bedienen,egal welche ! Jeder Einsatz ,alles passt.Du bist wirklich großartig!!Du liebst Deine Familie ,Du liebst Tiere. Du bist wirklich ein außergewöhnlicher Mensch!! Jemanden wie Dich möchte man zum Freund haben!! Liebe Grüße an Dich und Deine Lieben!! Grüße aus Deutschland 👍👍😁🖖🍺🍺
Gday Kurtis and Karen, thank you for everything you guys have done for use, this video shows exactly how things can turn to crap in a hurry and definitely important to show on camera to proof it does happen from time to time, almost makes you think the casting was crook from factory with the first crack appearing for no reason, great video mate, have a awesome weekend, cheers
G'day Matty hoping you are doing ok mate
The casting being extra dirty cast iron and bad from the factory was my thoughts as well.
Hey Matty, thinking of you mate! Be prepared for a roller coaster ride of emotions during this event. Wash off the bad ones and keep positive!
Mark from Melbourne Australia
Hey Matty we'll be there for you all the way! This was definitely a good character building exercise 😂 I think Kurtis handled it well, I was pissed off after getting that far to have it crack was so frustrating. We did notice that there were no cracks in the repaired zones so it probably would've been successful if the other areas didn't crack.
I was having my suspicions about the quality of the original casting and just maybe some of the treatment that machine had experienced for those cracks to develop?
We will never know exactly what caused the cracks, but it might explain why the machine was up for sale?
Mark from Melbourne Australia
It's not failure, it's a learning opportunity, Kurtis, we love your therapy sessions, you talk with authority and confidence during the work and you've got a dog. As an engineer, I love watching what you do, it's the best therapy I've found. Keep at Dr. Kurtis ❤
I recently had a repair on a grapple knuckle for a skidder. I only took a couple of videos. I don’t know what kind of cast it was, but was able to repair it and is now back in service. I regret not recording the process. Im a bit superstitious, and didn’t want to jynx the repair by recording everything. I do have a couple shorts and videos however. Thanks for this video sir. I’m glad I found this channel. Prior to this, there were no good information on this matter
Nice try, and I’m frankly astonished that you didn’t take it on at the client’s cost and risk - but I don’t know the business and who does what to remain competitive. By saying “fail = no charge” you are really putting your reputation up front. Respect for that!
Good on 'ya for showing that things don't always work perfectly in RUclips land.
It takes a lot of character to show when things don't go to plan, but in my mind it's really valuable to see the pitfalls. Good on 'ya
The camera work, editing, and story telling are just keep getting better. I learn stuff that'll never use in my real life, but Kurtis just keeps teachin ! Years of experience being passed on. Thanks for another great video.
Agree 100% !!!!
Im trying to catch up.
7 weeks in Hospital i ended up with a below the knee amputation. I also caught pneumonia, mrsa and co vids while being in ICU for over 10 days .
I lived through it all .I may only have one foot now butt i ready to kick ass .
Missed you guys alot 💛 A very Interesting repair. 👍🏻
Nice to see George of the Jungle back ❤
Wow posting a project that failed takes so much guts. Knowing how to accept defeat is the trademark of great est minds. I'm amazed. Great video, I felt those cracks in my spine, better luck next time
I can only wonder and fear what Homey would do to a pile of unprotected Christmas presents!
the only violence Homie ever commits is against packaging and squeaky toys, and he's getting really good at it
@@calebb5106
The way the fans love him, he's going to be kept busy.
Rubber chickens and pigs ears.. .Yum Yum...nom nom nom.
Lol
It would be worth the sacrifice.
AaaaHhhhm..,....open 'em up 😅😅😅😅😅there
What I love about this channel is that Kurtis is willing to show projects that don't go to plan, thanks for the videos.
my tears cannot speak for me... . that foolish box never stood a bloody chance... .. reckon that is the last time that box will ever talk back to Homie. Simply Brutal.
you're incredible Man .. the amount of knowledge you have and how professional and humble you are... WOW. .. Hi from Italy .. would love to shake your hand thou
You guys should do a field trip to the cast iron guy and interview him. It would be interesting to hear his thoughts on cast iron.
I got to give always credit to Kurtis for attempting repairs on new parts , nothing always goes as planned but there's always that chance something can go wrong...what you learn afterwards makes you better at what you do and were all right there with you helping you along....and Karen, also thank you for taking us along with Kurtis and our favorite 4 legged safety officer!
only 5 mn in, luv yur VJO's and work but that dog is pure love and happiness!!!! teo great VJO's in one!
Hello Kurtis, sending regards from Czech rep, I just saw a video with cast iron. I saw a video with cast iron where the usual problem happened. But i can tell you there is one option that has been tested for years(its over 50 years) . Cast iron can be welded even when cold. This procedure was used by welders in the Iron Curtain era where there was no access to better equipment.
When a thin copper wire is wound on the basic electrode along the entire length of the electrode. With this trick is possible weld cast iron when its cold.
The entire welding process is almost the same, when the crack on the material must be ground and cleaned, and you can start welding the first layer and then clean the slag. Always let the cast iron cool down after each welding and cleaning.
We was try this process on car. We tried this procedure on several exhaust pipes on the car and it always lasted. In most cases, the cast-iron exhaust ducts broke somewhere else
Good luck if you will tested this proccess.
I would say that casting had problems from the foundery. Like maybe the cast iron was cooling off too fast when it was poured. Great attempt at repairing it. Thank for you time. And Karen's hard work too.
Prime example of a good craftsman. He educates and shows what really happens in the real world and that repairs aren’t always successful. Thank you for sharing.
I only come here for the “right-o”s, the dog, and the crazy welding and machining.
What a diversity of knowledge and skill. It is a pleasure to watch you apply your trade!
Can't win em all Kurtis. Big props for having the stones to put the jobs that don't go to plan on show for those who want to criticise. IMHO, it just shows that not only are you and excellent machinist and Karen a great videographer and editor, but you've also go the ethics to back your words.
NOT ALL HEROS WEAR CAPES!
I can hardly wait for Mavel to knock on you door for the next MCU Blockbuster movie: “The Machinist vs. The Giggler”. Karen in the main role AND behind the camera. Kurtis quickly welding up a cage that even the Hulk can’t break. Homie makes friends with Groot and has his mobile toilet with him all the time. Disney getting their lawyers ready to sue them for the appearance of George and all his friends snuggling with The Giggler - who would have made a great Disney Princess. At the end Kurtis and Karen walking into the sunset and the train finally f*cks off.
What an epic movie :)
As usual - I just love everything about your work and Karens videography! Friday 9:00am in Germany, Coffee ready, time blocked in my calendar and constantly refreshing YT for the newest CEE video to appear. Now weekend is about to start. You three are a true gem on the internet. Keep going mate!
hahaha that's a brilliant comment, we can see how it might go like that 😂👍
Listening to those birds it sounds like I'm watching a Drain Addict video. Great work, both of you.
Congratulations for publishing the failures also, honesty and professionalism are two rare values today, you represent both at the highest level.
I really appreciate your work and props to you for showing that not all repairs go as planned!
Keep up the good work mate!
It's nice to see that with all your experience that things don't always pan out & you're prepared to show it.
*I really appreciate the zero drama, zero clickbait, honest repair work, well it didn't work this time but it usually does aspect of the CCE youtube channel. And watching Homeless tear open his Amazon boxes is pretty great too.*
Love seeing cast iron repair! I know you don't like doing it, but man it's a skill that is going away and shouldn't. Nothing is going to replace cast iron, so it's sad to hear there is only 1 guy in the area who has great success at repairing it. We need him to share his knowledge before it's gone!
EDIT: Not saying Kurtis did a bad job or something like that, it was brilliant. Learned a lot of little things watching this and love that he's doing it.
Agreed! Kurtis is hoping to get a meeting with the cast iron specialist and get tips/advice if he's willing to share any
I have a textbook from Linde Air that has a section on cast iron repair. The book is from 1943. If you're interested I can try and scan the relevant sections and send it your way.
I learned a ton just watchng how Curtis found all the cracks and ground them out. And watching those cracks form during cooling down was heartbreaking, but tells me what Curtis already knew. I suppose a repair on this massive piece has to mimic how it was cast in the factory - getting the whole thing hot - really hot - and then letting the heat escape gradually over days, not hours. I do wonder how it got cracked on the machine in the first place.
@@CuttingEdgeEngineeringwas wondering if you had any contact with the other guy, if he had given you any advice etc. I don’t weld or machine but I can look at a piece of cast iron and it will break. Love your videos.
@@CuttingEdgeEngineering I'm wondering if you could bring this video with you and to see if he had any suggestions, if he's the only one and booked months out, likely would love to have another who was also taking the never-ending work to help. Maybe try for some time outside of work to chat would be better.
Hi Curtis, you can’t win them all. CI is very difficult to repair by any method. Thanks for showing a job that did not go to plan. Always enjoy your vids. Thanks from the UK.
oh, wow....
it's the first time I see you "not being able" to finish *today's job*...😮😮
cheer up...
with every fail, you learn something new, and that's always positive..!!!
cheers from Ibiza, Balearic islands, Mediterranean sea, Spain.
Nice warm job in a hot climate sweating your nads off 😂 you can’t win them all, I do enjoy watching your repairs
Honesty and customer relations is your reputation. Your rep is great. Cheers
I see Homey is putting his Australia Post parcel sorting skills to good use.
Hey come on as an ex Aust Post employee I absolutely resemble that comment.
I think it's the same the world over, actually. Except here in the States, the postal workers steal checks out of envelopes, "wash" them, changing the recipient and the amounts, depending on what the check was written for.
Could get a job with UPS but he would have to destroy them a little better.
@@michaelmcclown5593it wouldnt be an Ozzy post delivery if those boxes didnt came looking like a football 😊
@@tetedur377 lol take a tour a big USPS sorting building. You would believe the security in those places... while they might have some bad apples slip through they are hardly what you appear to imagine. They employ security like a prison or money printing operation.
I think the only way to get a multi thickness, worked and drilled part like that to take a repair properly would be with a lab oven, with a sliding window that could be opened directly over the area to be repaired and closed again for it to be able to be brought back to room temperature over the course of 48 hours. Doing this on a part with that many internal stresses at a bulkhead of stress like a milled hole with drilled threads is pretty much impossible without absolute uniform temperature control and a temp curve several days long. Kudos for posting this kurtis! Many would not have
On voit les professionnels à leur capacité à analyser leur travail. Il n'y a pas d'échec, il n'y a que de l'apprentissage. Très bonne vidéo sur la notion de prise de risque et comme on dit chez nous"il n'y a que ceux qui ne font rien qui ne font pas d'erreur", même si dans le cas présent, c'était un essai risqué pris en accord avec l'entreprise. Merci pour cette vidéo qui nous rappelle que la technique n'est pas aussi cartésienne qu'on voudrait nous le faire croire et qu'il y a souvent des aléas.
I feel like this video deserves some kind of an award.
Not only do you not monetise the hell of your videos like some RUclipsrs, not only do you post videos of true ability (kudos to the slowmo editing too), and not over excitedly blown up out of all proportion, but then you go and post a video as honest as a genuine failed attempt! Gawd bless ya govnor! You've really earned a like on this one, and already a subscriber, I wish I could do more, but I don't have the mates to share it with. You've really earned my respect on this one though!
Top video Kurtis! Top video!
Let's not forget Karen. Doing a great job is nothing without someone equally good at filming and editing.
that was commendable in so many ways, the fact you admitted your lack of experience with that particular part, the fact you took it on to try and help the costumer, the fact you showed all the difficulties while working it and the finale (the failure of the part to hold up) mad respect to and the Lady for another fantastic video.
Great video with very accessible explanation for the difficulty of all of the repairs that you do. This is a complex part that was designed to be easy for the factory to produce, but not necessarily practical to repair. I am another of the retired engineers that enjoy the channel that the two of you have created. I think one of the most valuable things is that Kurtis has a deep and practical understanding of the metallurgy of the parts under repair. This married with the deep understanding of the machines and the stresses on the parts in their application on these large machines is very powerful. Kurtis has obviously spent a lot of time in the field working on these machines and understands the application of the parts and the challenges of operating and maintaining these machines. This repair was very ambitious and Kurtis communicated this to the customer. As many have said, knowledge and mastery of the art is not just built on successful repairs, the failed repairs teach many lessons too. Kurtis understands the parameters to control and did the best job possible to prepare for a successful repair. Who knows what all of the stresses were inside this cast iron part as the evidence of the failure of the machine was not known to the new owner or to Kurtis. Great video to show the learning process. In several years, Kurtis will be one of the grizzled grey bearded old boys who have 30 or 40 years experience built from actually doing repairs and collecting feedback from your customers. The effort to understand the failure mechanisms and to rebuild parts better than they left the factory is very impressive. Good work. Thank You both for the very enjoyable videos.
I’m a welder and have tried cast iron repairs but unfortunately more failures than successes until I have used eutec chamfertrode rods with preheating “of the whole piece” not just the areas to be repaired then covering the whole piece (inside and out, all sides, etc) in “gold cornflakes” a insulation material to hold the heat in while it slowly cools.
Doing this greatly improved my success rate but still no guarantees of success.
Props to you for showing what it’s like to deal with cast iron and the failures that go along with it
I’m always impressed with the level of caution you accorded to these cast iron structures. Now I understand better why that’s the case.
Started watching your videos about 2 months ago, I'm now caught up on everything. The work you do is amazing and the manner in which you deliver it to your audience is superb! Cheers from South Africa! 🍻
hey mate welcome to the channel, glad you're enjoying the videos!
@@CuttingEdgeEngineeringthat loud PONG from the housing even made me pucker
I've never seen a safety inspector so excited to go to work. He's a good dog, and thanks to y'all, living a great life. Get some, Homie.
I feel for you on this one. As an apprentice back 50+ years ago, I had some work for the ASTM here in America. I had to make test pieces made from pieces of failed castings of all kinds. Even normally very reliable manufacturers have castings that have uneven or unusual stresses in them. This part sure looks like that might have been the case. Once they start cracking, and no abuse or damage is found, it's not often you can make it right again. However, if you have the time and facilities you can heat cycle the casting in a very high temperature controlled annealing furnace and possibly make it more stable. When we had parts to make out of cast iron that were designs that would be prone to cracking, we had an ancient blast furnace door that we salvaged and the iron was so dead and stress free that it was stable as heck in any configuration. A little bit of work handling and cutting blocks from it, but you just couldn't buy any young cast iron that would do the trick. I even made some tools from some of the smaller scraps. But cast parts take real skills to keep them stable. I think that's why cast steel was much more popular back then. Great try . Love this show.
Really tough job - respect for trying it in the first place.
Brilliant that no charge to the customer showing integrity. I do hope the customer acts with similar integrity and flings a few slabs of beers your way.
Homeless is a BEAST with that parcel - laughed out loud.
Best outtakes this year! 👍
I wonder if the impurities are related to probability of cracking. I understood how heat expansion but never thought that it would cause that many cracks. Was amazed at how many appeared, and where they appeared. Was expecting more in the corners.
I guess a massive oven would have been helpful, along with a bulk load of sand to hold the temp high for the body while it was being fixed. Given how difficult this would be, wonder how the other guy does things of this size.
Even with the sand you have to be careful, ensuring that it is clean and dry. Cast Iron is a nightmare. 😢
I must say watching your videos makes my day so much better. I love homie, lately my life has been quite a depressing mess. thank you for sharing!
The filming and editing are amazing.
I really appreciate you showing that mate. A lot of channels would have binned that video. I’m glad you show us the trials and the successes. As much as I enjoy your videos and the work you do, I arguably learned more from todays video than the rest. Great video. Keep up the good work. Cheers
What I like about this video is the honesty Kurtis has when accepting jobs like this. He knows his abilities and limits and does the best of what he can to satisfy clients. Though it wasn't a successful, a lot of learnings can be taken from this.
Keep the videos coming CEE!
Fantastic vid Kurt, takes abigger man to show a fucked up job rather than hide the bad jobs and only show good jobs.
Total respect to you chap.....
Great vids and very educational too.
Hi Kurtis, I have seen these works done many times. Where I come from there is a workshop that has specialized in this sector for decades. The failure is due to the preheaters. They were insufficient and not uniform. When working with these pieces, you need a gas oven to accommodate the entire piece. This oven is open on the side where you work and always remains active.
The piece must heat up for many hours, also to eliminate humidity and oils.Only then are you sure that the temperature is uniform, correct and the impurities are eliminated. Then let everything cool gradually, always with the oven turned on. We all make mistakes and we all learn, but in this case it wasn't your skill, you needed better equipment
Been watching Matty's channel for a while and was very shocked to hear about his diagnosis when he let us all know. He's absolutely amazing how he's dealing with it and still out; n the workshop making videos. We are all wishing him the very best and hope he gets the all clear simetime in the near future.