100 Year Old Broken Gear Brazed Back Together
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- Опубликовано: 29 сен 2024
- I received a couple of parts that were badly broken that come off a Silver Manufacturing Co. post drill press that is 100+ years old. The gear and feed arm were broken during shipping and will need to be brazed back together. In this video we'll work on the gear. I use a combination of fixturing and clamps to hold all of the parts together for brazing. For the brazing filler rods I am using my Eutectic Xuper 146 XFC premium brazing rods. These are high quality rods that will provide good strength for the life of these parts. Because of the amount of work needed for these parts this will be a multi part video series on the repair. #abom79 #brazing #industrialrepair #gear #vintagetools #oldtools #postdrill
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My dad was a certified welder with a degree from Ferris. He told me the torch never stops moving in brazing, and your to use a near elliptical pattern across the weld to draw the braze into the joint by moving the heat across it. With this method i have never failed to braze anything properly, still use his old torch set.
The best close ups of brazing cast iron I've ever seen. Assuming Abby gets the credit there :) I like your new shop, but always feels like coming home when you're here.
I’ve not seen brazing filmed this clearly before. I could clearly see the interaction between the flame and the rod. This should be a standard for technical schools.
*Trading schools
@@kramler If you really want to get picky about wording, "technical schools" is better than your suggestion because presumably a "trading school" would train someone selling stocks. The "technical schools" were, once upon a time when some of us were young, called "vocational/ technical schools" and included a significant amount of skilled trade coursework. Metal shop taught machining and welding. Wood shop taught some framing carpentry, some finish carpentry, and fine woodworking. Portions of the time were carved out for the students to get academic credit and actual on-the-job training in their chosen trade. Some no longer teach the skilled trades, but many still do.
Did you miss the parts where he says he screws up. Or his monologue in part two where he blames out of practice, been years, oh the hub may not be centered. Did you even watch before commenting?
@@jerrylondon2388 perhaps we have different views on education? I think showing things where someone eases up and admits it. That can give someone more confidence to admit their own mistakes.
@philipallard8026 Then you will love part 3 where he doubles down and screws it up even more. Then finally asks the owner what kind of repair they want, wallhanger or useful? Then proceeds to do his usual "good enough" repair in a rush to get it out of his shop! "World class" I had to put that in there for the fanboys.
Best video brazing I have ever seen. I am not even a welding/brazing apprentice, but I love learning something I have no clue about. Most videos are just a bright 2" blinding light. This was good. Thanks.
No blinding light because it was brazing, not welding.
I usually set my torch lower when brazing with bronze so that bronze only melts on the nail pattern of flame at the tip of your torch, that helps me keeping the torch at a same closer distance (not moving back and forth) without melting anything else than the bronze rod. I'm sure your method works fine too, but it's what I learn from my dad who is great at brazing with bronze. Thanks a lot for your awesome content!
I would highly suggest looking at Instapack bags for these expensive parts. You do the mix procedure, put them in the area/box your trying to protect. Will save you a great deal of time packing, and when you choose the right densities, its hard to get wrong.
Love the camera work up close... First time I've ever seen brazing. Looks a lot like soldering, which I've done a lot of, just a LOT hotter.
Brazing IS very high temperature soldering. While quite hot, the base metal is not melted. In welding, the base metal is melted. The bronze alloys used in brazing are comparable in strength to cast iron, BUT the difference in cost between ferrous material (low) and cupric material (high) is SUBSTANTIAL.
Great job, and super camera work. Was that Abby? Such a difficult thing to film with such huge differences in brightness. Cuts of this would make a great tutorial video with an explaining voiceover.
What a great video. Loved watching you working to control the puddle, loved the camera work that allowed me to watch you working the puddle. Most excellent team work.
I'll be honest, brazing is usually about as fun to watch as watching paint dry, but the way you filmed this was fantastic. It was cool to see the braze flow in the joint, and definitely made it more interesting to watch. Keep serving up different perspectives on everything you do! I look forward to every Saturday when a new video drops!
That thing was smashed, literally, into pieces!!! Amazing brazing job, man. Much respect from Texas.
I love Brazing! At work one time many years ago the shipping guys knocked a Toledo scale off the counter shattering the cast iron cover on the base! The scale still worked fine but the boss asked if I could fix it. Must have been 20 or so pieces. Now fit them all back together. I got it done but it took a while!
And @1:54 Forklift "Squirrels" really piss me off! They go running around full throttle like it's some kind of game instead of a job! I have two certs, regular and all-terrain, and I did NOT EVER try to rush the machine! My job was as an Engineer so I had to be certified for everything we used, from Bobcats to small Cranes! Just to move around the parts for things we were building! 😆😆
am farmer so repair stuff all the time. this vid really helpful. thanks
Looking good and strong Adam, be great when its all done and cleaned up.
Thanks Adam. Great Video. We appreciate your hard work on these.
You did an awesome job on this repair and an excellent video! The camera work really captured every step of your process. Well done, Sir!
Somewhere Rucker is smiling! XO
Great camera work Abby.
That breaks my heart, excelent repair!
I wonder how well the hub is aligned with the gear after the repair - the newly formed crack was awfully wide. I'd probably clamp the wheel upside down so it registers on the gear teeth to make sure the setup is in plane, and indicated the whole thing on the mill for concentricity.
You're the man Adam, nice work
As alway it's good to see you do your great and qualty work lear alot from you Thank you
Adam, nice weld job. Nothing against your new shop, but I always like watching you work in the old shop. Must be the older equipment and the way the shop is set up. I like old stuff....
Quincy, Massachusetts
You did a great job. You did have a little hic-up but that’s welding. I’ve been a certified welder for 45 years and you name it, I’ve welded it. Cast iron is the most unpredictable metal to weld out there. Trust me, I know. I’ve tigg welded cast iron many times but gas welding it on pieces like you have is the ticket. I really enjoyed this video and glad to see somebody has not forgot a dying art. Just my opinion but when you dealing with cast iron, while you are welding it, keep a constant source of heat on the piece. I know it will be hot, but it might, and most of the time it will, keep you from having to deal with extra cracks. I’ve watched that junk crack right beside my weld before. If you heat it up and keep that heat constant while you weld, it has already expanded as much as it can and makes it less likely to crack. Just a suggestion and this has been my experience.
Great craftsmanship! As always 🙂
Homer Simpson: The word unblowupable is tossed around a lot these days...
The same could be said on Abom's brazing.... it it textbook. I learned a lot just watching this video.
Way to go Adam! How cool that you use your experience and resources to assist someone that would have had no other option. To me that is where the different RUclips communities really come into play. People like you and Keith Rucker, etc. really make this enjoyable content. Not to say we don't like the everyday machining, but doing it with a purpose and a little sacrifice is what gives me faith in humanity. Anyone can cut something into pieces and drill holes into it, but when you build with purpose, and there is a bigger objective to accomplish, that is where the real satisfaction comes to seeing these projects become a reality to someone else's life.
Love the presentation and content. You Sir a master of metal! Fantastic film work, great....Just great (I think this was a great balance with CNC content as well.). Appreciate you both, stay safe!
Nice job good to see you interesting old shop
It's nice to see you using that Welding Table like you made it was one of the first projects I watched you do how long ago was that??
Nice work, Adam!
Great job Adam.
I think what Adam was saying at 14:00 that the Tig method of brazing was too hot and was welding on the base metal. As a person who enjoys metal casting I was thinking that making a model of the part would be a great project as well. I will watch the rest of the video.
Beautiful repair.....
It reminds me of the time I arrived at a freight company to collect a watercooled UV Laser that was worth the price of two houses , just it time to see a truck driver throw the box it was in onto the loading dock.
A guy delivered my 65" TV, and I saw him wheeling it up on my concrete porch through the window. He stopped by the door and tipped the TV over, and it hit with a loud thump. Luckily, it worked and I could find no damage.
Looks very good to me. My old man claimed that inspectors wanted to see 80 ripples per inch. I've sure never seen that. Maybe a straight run by someone that does it daily.
Pack for nuclear war - that's my mantra. I imagine whatever I'm shipping being kicked out the back of a truck, then ask myself if I've packed it well enough. Not had anything arrive broken (yet) in over 30 years shipping aircraft radios. A bit of luck helps of course. Love the amount of care you take with everything, it's especially nice to see this vintage stuff being cared for.
I kinda want to make the point that the guys running the forklifts are often working low wage, long hours, easily replaced, have a huge amount to get done - i don't want to say they are not at fault, it's the entire system trying to save money on costs that's at fault.
As you say, you gotta package things up and make them strong because the delivery company has to do what it has to do.
yep and the delivery drivers are trying to meet quotas from their bosses that cannot be met if you treat each package with care.
Great video
16:15 to 17:17 is black screen with no audio.
The video works great for me. Maybe your PC is broken?
@@swedishpsychopath8795 maybe its not broken did it with me too
@@mallyuk1 But what if both of your PC's are broken?
My iPad is broken too then
Here, too.
Beautiful
how do you know the hub and the rim are concentric and coaxial?
That's the difficult part when the only machined part is the bore.
@@TheManLab7 arent the teeth machined
@@cheater00 They are machined, but not to the precision of a gear that has to mesh with another gear. The bird beak pawl only pushes against one of the teeth at a time.
@@cojones8518 that doesn't look like a pawl gear, those are straight, and often they also have ramp shaped teeth. even if they're not ramped teeth, the teeth look very different to the ones on this gear. this gear has teeth made for meshing with another gear.
34:25 yeehaw look at that flux go
is there another crack unground?
I have seen a parcel handler in a temper tantrum throwing the boxes across the dock/room like they were a football..
This is a Craftsman at work.
Makes me think of Kintsugi.
thats a Dope watch... 👀
Nice work Adam and Abby. A tricky part to weld as expansion and contraction were going to be a challenge with four spokes to fix.
@@ArthurDumesnil yes I realize that, but either way the part is subject to a lot of temperature variations.
side project make smaller clamps.
53 mins, Abomb? Challenge accepted!
Please feel free to mock me but I’ve seen super glue used a lot on various different Chanel’s for fixturing.
Would that not be an option for this type of work to save the extensive clamping that Adam had to do for the initial tacking?
superglue releases at moderately high temperatures. It would probably fall apart midway through the brazing.
Sorry, I should have been more specific. Use glue for the initial tacking.
Tell me, what is your favorite type, brand, and grit of sanding belts for metal
Adam, you might have the customer send your finished repair to Windy Hill Foundry as a pattern to cast a new one as a spare just in case.
You can't typically use an existing part as pattern if any of the dimensions are critical because the metal shrinks when the cast cools. Also, any surface that needs machining will wind up even smaller. Clarke has mentioned that in many of his videos. If necessary, it would be better to scan the part and make a mold increased by about 5% in size. But brazing something like this should be perfectly fine.
I remember learning to braze with Oxy-acetylene in the 6th grade,... in the 70's when things were cool and kids could be curious! ( a small hammer that I still have in my tool box.)... It is so sad that kids do not have shop classes these days in school. I developed a love for tools and craftsman skills in my 6th and 7th grade shop classes.. Woodshop and metal shop... We cast belt buckles, spot welded, bent steel and used machinery for candle holders, and in woodshop made family signs for our houses and learned the tools and the methods of building from wood..... I have all my items from shop class... They are very cherished items... I hope one day kids can once again learn to manufacture and build... It is a skill very much lacking in our kids education!!
I too went to shop in high school in the 70's. In the 80's the education system got into "social engineering" along with liberal political movement and one of the first things that got sacrificed on this "alter" was the technical shops.
From 16:15 to 17:15 black screen....
I was getting ready to say the same thing
Same here.
Adam, Abbey is not only a beautiful woman but an excellent camera lady too, well done both of you. Joe.
In 1962 just out of high school I worked at a farm machinery repair shop in Wrens, Ga. My first job at the shop was to make long brazing rod out of short ones.
Wow. Abby sure got some great close-ups of that brazing. Some of the best I've seen. Many thanks to both of you!!!
The internal stresses will make this repair crack on its own. The entire part must be raised to the red temp.
Great camera work Abby !!!
Yes , that was AWESOME
Thanks Abby !
It used to be occasionally an item would go missing and they would track it down or you’d hear about something that got damaged and they would be rare instances but now practically everybody who uses the mail or a shipping firm has multiple horror stories about receiving empty boxes or damaged parts over and over again. It’s no longer uncommon it’s par for the course. It’s an exception if you get your stuff or get it undamaged. The goons they hire are the sloppiest people who can hold a job. What’s this country becoming?
I don't think those people are necessarily goons. If this problem is consistently getting worse, then it's systemic. Probably higher work pressure.
It's not just in the US. There are certain courier companies that, here, in the UK are staffed by people who just don't care with a management structure that aren't bothered either.
How is it that I can get stuff shipped from China for almost nothing that arrives in perfect condition but couriers can't ship something from one end of the country without damage or it going missing?
It’s that the corporations who own them only care about efficiency and profit. Not quality. They have planes, trains, and trucks scheduled down to the second. The guy on the forklift has no chance to do quality work or they will be out of a job fast.
Pay peanuts get monkeys, simple as that.
Cost engineering isn't just putting plastic handles where there used to be aluminium, brass, or steel.
It's also the work conditions and incentives they inflict on the people trying to earn a dollar. Most people would like a secure job that treats them as real people.
From 16:14 to 17:17 there is a fallout of the video. It's not your internet connection that fails 🙂
The close-up camera work is just incredible! Many thanks for bringing us in close, from all of us who will likely never experience this firsthand!
Think I would have bored out the center of the gear and fabricated a whole new hub using 3/8 plate. Those factory spokes were too light to begin with.
This is an antique.
If its just for looks, to represent an era, then understandable to restore it.
@@douglassmith2055But at least do a good job. Abom is really bringing nothing to the job. He seems to have a limited skill set, like a former assembly line worker. Really good at one or two things repeated thousands of times.
Adam, I'm a licenced forklift driver (although it's not how I put food on the table at the moment) and I always operate on the principle of "how I would I like to receive this if I'd ordered it for myself?" and behave accordingly, I work in a supermarket doing the home delivery but sometimes I also do shopping and I use the same idea, "would I buy this for myself?" it doesn't take much effort, physical or mental, to do things properly, some people are just lazy.
My father used to work with safes and they were always coming in damaged and having to be returned, because fork jockeys and truck drivers see a safe and think "oh it's metal, it'll be fine" or "it's metal, it's heavy and doesn't need to be secured as much as the manufacturer specifies" not realising that a lot of the time the skin is relatively thin and the interior material, which provides the fire resistance, breaks from shocks and big impacts which compromises that aspect of it, making the safe worthless and unable to be sold.
You need some Cleco Clamps for that. Originally developed for the aircraft industry. They are used across many industries now. There are many different formats of the Cleco clamps from hole type to hold sheetmetal aligned for assembly or jaw style clamps. I have collected a large supply of these and found they to extremely useful in all types of situations. Always amazed at the quality of brazing you can accomplish. Thanks for sharing.
P.S. Glad to see you back in the original shop. You seem more comfortable here.
Hey Adam, your use of the TIG welding equipment begs the question, why don't you fusion weld cast iron repairs with nickel filler.. I have been doing TIG/Nirod cast restoration work for many years. A TIG/NiRod repair gives a good color match for restoration work and i've had 0 failures Just a thought, thanks for the great content
He says in the beginning that he thinks his chosen brazing method works better than TIG with nickel rod. Might make a neat video to demonstrate why
I guess he prefers to work a way he knows than experimenting with customer part
Great job filming the brazing process!
Why does it squeak every now and then?
Are you going to build up that tiny bit which chipped off on that square bit where those 4 pins sticking out, even though there's currently only 3?
Good day noble Adam. Excellent repair work. Oxyacetylene Oxygen is still a wonderful repair weapon for all welds.
I have some extremely fine oxy-fuel torches in my arsenal. Also try a Dillon MK3 / Henrob Torch. It takes a little getting used to in handling, but it is a very special device. With such a burner you can save a lot of gas / oxygen. He has a very soft flame etc.
I also weld lamellar (lamellar graphite) cast iron mainly with Castolin / Eutectic / Eutalloy welding consumables. It is one of the best welding consumables with the longest & best experience in metallurgy.
I always have very good experiences with welding additives of the same kind, for example = Castolin 14 or with = UTP 5 in hot welding. They are of the same species - cast iron welding rods in 4.00 mm or 5.00 mm.
This is then no longer brazing, but welding.
I really like your old workshop. That's how I've been working for over 42 years.
Warm regards from Lake Constance / Switzerland
:walter
3:10 You're right the cog and pawl are part of the downfeed. As you crank the handle to rotate the drill there's a cam that engages the pawl's arm and it advances the downfeed screw a couple notches to put pressure on the drillbit.
It works sort of like the table crossfeed on your shaper.
What I find interesting is it kind of hammers the bit down into the work one chip at a time rather than a continuous feed. I think this would probably give advantage when drilling steel with crappy carbon steel drills of the time, encourages a less than capable bit to dig in and make chips rather than rub and burn.
Awesome! Love the old shop stuff. I miss the big projects you used to do at Motion. Been following you for a long time.
Adam, the great closeup camera work (Abby) on your brazing should even aid you, perfecting your own skill as you watch this video playback!
Keep up the great work, we appreciate you.
I can remember the early SNS days when you were planning that side extension, now you have another shop and over half a million subs.
What a journey.
I like the old shop!
Interesting video, as always. Too bad that undetected crack didn't get tacked with the rest. The gap grew kinda large. Hopefully the final brazing didn't pull the gear out of round.
Maybe testing for cracks before starting? It's so simple a 6th grader can do it. He still needs to check before going further..
I've used the techniques and processes you've demonstrated on your channel to sucessfully repair several damaged or broken castings. Thank you for taking the time to demonstrate and share your knowledge.
I also enjoy you taking the time to share your desire to expand your knowledge and experience in your new shop, despite those that may not be as into it as the rest, even to the point of being rude. Again, thank you for shairing on YT.
Nothing beats a bit of Abom79 after a long day at work! keep up the great work!
All the people who work in the shipping industry see is just a box. They're underpaid and overworked wage-slaves who just wanna get through the day. Their boss probably yells at them because they're not moving fast enough. Some of them probably have to work multiple jobs. Please put yourself in their shoes and ensure the package can withstand a little bit of abuse. I know it sucks, their job sucks too.
Never seen anything like this before. Fascinating. Brilliant camera work. Thanks for sharing.
Same way my dad taught me to fix cast. Also enjoyed the video from the home shop for a change. Thanks
Absolutely, the worst that I've ever had to deal with was a maritime satellite antenna assembly that got forked. It was on a beautiful skid and boxed with 1/2 or maybe 3/4 plywood. But at some point in shipment or storage at our site. There was a fork blade punched through the box that left a gouge in the gel coat and glass mat. We got a decent repair of the dome using a repair kit from West Marine, and with the dome in place, you can't see the repair. Honestly, after it was repaired I had trouble seeing the repair from 4'.
Nice work. It wooks like the gear was tied to a lead weight, and thrown out of a 747 at 40,000 feet onto a concrete driveway. Terrible terrible treatment.
AMAZING! You sir are a master at your craft. I went to university of Miami with a scholarship but working with my hands was what I really enjoyed, so I left the university, tried other jobs and became an electrician, so for 45 years that's what I did and never looked back. Best decision of my life. Was never happier. Once you find yor niche in life it gets easier.
I'm not a religious man but as far as I'm concerned that is gods work😊 so good to see the prep work, attention to detail and professionalism.
Nice to see you back in your old shop.
The camera work was just as good as the repair.
Abby killing it with the camera today!! 👏👏👍👍
Might want to put him in touch with Clarke over at Windy Hill and see if he can get another one cast, bc I have a feeling as old as it is that more cracks are going to develop, not on where you brazed but in other sections just bc of its age. 👍👍
you mean in touch with Karen and Kurtis at CUTTING EDGE ENGINEERING AUSTRALIA...the best
@@SalvoMorina CEE doesn't do casting though?
@@dolvaran you are right, but CEE produce the best video in machining community ever...
@@SalvoMorina Can't argue with that. Karen is excellent.
If you have hundreds of thousands of dollars of new CNC equipment, why would you cast a replacement part. Even after a successful casting, you still have to machine the new unit. You need to spend hours or days designing and making a model to create a mold. Even then it may fail spectacularly.
I just inherited my father's shop full of tools, some of which I have no idea how to use. Watching you has taught me a great deal. I look forward to learning more about how to use some of his equipment, some of which I remember from my single digit childhood. Thank you for your clear, easy to follow descriptions of what you're doing.
Looks like machining is problem-solving. The more skills, knowledge, and experience you have the more problems can be solved. Thanks Abby for the killer filming!
Fork lift drivers take pride in their work too- I was often chosen for ticklish, expensive work. You don't get good work for minimum wage. But if you saw how some folks pack their stuff...
I love the look of brazing. It's like that japanese art of repairing ceramics with gold.
Nice camera work!
I believe that is well done enough to qualify as Art.
Outstanding camera work! Great job Adam.
shout out for the camera person!
Love the new shop, but really good to see the home shop.
Adam, this is the best brazing job I have seen you do. When Abby grabbed the camera she followed the torch so closely. It was like "Blazing Saddles" and "Ring of Fire all at once"!
Did you count how many times he admitted on camera he screwed up? And yet you're fanboying "the best brazing job!"
Step 1! Dye Penetrant Testing. Determine the scope of your work! It could have a dozen cracks you cannot see. It's not a child's jigsaw puzzle. It is a brittle metal that was dropped. He still needs to test for crack before proceeding. "It's cracking!" No, it was already cracked. You didn't do your prep work! Not professional. Clearly, he did line work, the same thing, all day, every day. Your general skills never improve, except that one single skill is great. Brazing, is not that skill. Nor was job planning. That is why he can't learn CNC, it requires job planning and problem solving in detail.
You haven't seen much brazing, then
I would maybe try Windy Hill foundry, Soo if he can cast another one, fix this one best as possible, then get a replacement cast,