HUGE welding repair stresses me out ! ten ton and it's broke in half! HEAVY ENGINEERING!
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- Опубликовано: 11 окт 2023
- thanks to Karl Casey @WhiteBatAudio for awesome tracks as always !
check out his channel helping us creators!
PART 1! .. THE FIT UP..
SUBSCRIBE FOR PART 2 :-)
/ allistairc123
this was one of my most stressful jobs yet because it was a ten ton steel casting!
and it was completely broke in half !
I said I could repair it then I was worried I bit more than I could chew!
hope you enjoy my step by step welding repair in our engineering shop with lots of weld action even some big machine tools at the end of the project!
#brutal #engineering #welding #repair
#machineshop
if you want to see what this machine is , here is an example showing operation...
/ allistairc123
• Jaw Crusher Assembly V...
• Jaw Crusher Machine
here is video of the last one I done..
• 20 rolls of welding wi...
more great welding and engineering channels
check out @ICWeld and of course @CuttingEdgeEngineering
in honour of men like my dad sammy and Fred that have gone before me ..
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An old toolmaker told me years ago “ some day they will bring you a job. No one else will want to attempt it. You won’t know how to do it but you start any way. While you are working on it you won’t be sure if you are doing it correctly. When you are finished you won’t know how you did it but it will be right and your best work”. Very well done sir, Mike
I’m 67 retired certified welder/fabricator.. I’m impressed with your smooth gouging strokes means less grinding! Impressed with your fit up! I’m like you I hated grinding. When I first began welding I cussed the grinding! An old timer told me learn how to use the cutting torch right! So he showed me what I was doing wrong. From then on I used my head. I tried to use the gouged as if it were a milling machine,,,,,,,less grinding! Graduate of “The School Of Hard Knocks”! Thank you for your videos!
To avoid nightmare jobs....stop being a master at what You do :)
Oh how true!
Indeed
😂 so true, when you’re good you get all the shit jobs no one else can do
@rolfmissing4554 I'm a master at my work also! Master Fugcup sometimes but I'm a Master nonetheless🤔😜
I know a guy who is a Master Baiter. He does a lot of jobs, all by hand.
I found it refreshing to hear you find an old repair weld and understand that it was probably not made in ideal conditions. It is easy to be a critic but it is much better to be understanding. I take pride in my work and I like to see others take pride in theirs, but I was not always good or had good options, so I have less than ideal work out in the world but I try to learn and grow as a technician and now a trainer/ supervisor.
So easy to criticise jobs done by others. I use to be like that when i saw poor welds here and there, and im not near to be a competent welder myself. When doing my welds, this actitude came back to hout me. Id rhink about someone else critising my job, bot being aware of the cheap equipment, working off grid andwith shitty rainy cold weather. This video and your reply, Brett, gave me so much peace.
@@jaimemanerodelpino634 Been there, done that.
@jaimemanerodelpino634 Better to give the guy before the benefit of the doubt with sub-optimal equipment or perhaps trying to do it on-site with a lack of equipment. It's not going to get the job done faster if you are cross with someone who isn't there to hear you cursing.
well said
I'm curious as to the history of the previous patching, was it days or months old? I won't say repair as it looks like it was intended to mitigate existing cracking.
"If you don't feel uncomfortable, you aren't growing"
Thanks for walking us through this beast of a job, I really appreciated hearing your thoughts and concerns and how you worked through them.
Seeing an open bucket of 200 gouging sticks slowly get smaller and smaller gives a sense of scale to the amount of prep to be done!
Half inch non the less
He should have just used epoxy resin and gaffer tape. Would have been a whole lot quicker.
Wow Ken can't stop laughing 😂. Hey didn't they use that on the Space Station too. Ha ha.@@KenFullman
As a fabricator I found this very interesting. Can’t wait for the welding one. Much appreciation for putting these out.
being a heavy machinery mechanic that does field work i really appreciate and admire your attitude towards not judging other people’s welding because you are so very correct and you have no idea what situation they may be in so i appreciate that.
I really enjoyed that 55 minutes. What puts you in the same league as Issac and Kurtis is that you care about the job, as they do. I can tell that you care by how you still get nervous as you take on a new job, even with all your experience. I hope your employers and customers realise how much of you is invested in each job. 👍
BTW I bet that broke with a hell of a bang, probably a code brown for the operator 🤣😂🤣
i watch curtis who is issac? so i can have a look
@@simonhughes3705 @ICWeld
Ic weld
I thought is was Kurtis?
Curtis is cutting edge engineering
Years ago a fella in our works work shop said always wear a mask when grinding , when I asked why he replied use a grinder at night with a big spot light to see how much nasty stuff come off from the disk - grinding process . I did as he said , now I know what he ment and why you should always wear the mask as you dont want to breathe the nasty stuff . Great video by the way I'm going to come back to see what you and you channel does next .
Yes the noise is frightening, I used to do similar work on fork truck weight's 50 years ago. also the smoke, not a nice procedure
I hope that your adding in " the human factor" helps people realise there is much more involved than just glueing two bits of metal together. Awesome video, can't wait for part 2 👍
Thanks for the transparency with the amount of stress you experience doing such a project. I thought i was alone with loosing sleep on project that are way out of my league (or I think they are). Good for your for challenging yourself and setting the bar higher.
Love the fact that you mentioned Kurtis and Karen. CEE. Also I felt for your hands, I laboured on a site once, separating temp cabins on school grounds and for three days after I couldn't even hold a spoon. I love your drive and vulnerability over this job and others I've watched. A working man if ever there was one. Respect
really respect the consideration of the previous welders work. shows you understand the field work and how hard it can be! the customer will always want an easier / quicker repair but sometimes its the bad choice in the long run!
A "scientific test" that involves a sledgehammer?
A man after my own heart, right there
The sheer weight of the machinery is 😳, hats off to you all you guys who work on these heavy duty machinery. 700tonnes of rock crushed per hour, wowzers! What a great job imo. I naturally have an interest in this and enjoy learning.
Your worries are completely understandable ; the pressure is on YOU . Repairing is always a risk . In our shop we make sure the client understands the stakes and they make the decision . We guarantee the quality and the effort but not the results .
Yes, it's got to be arranged so that the customer understands the risks, that the work has to be paid for more or less regardless of the result & is kept constantly updated on how the repair is progressing & what decisions have been made about the repair process & gets to agree & accept full responsibility at every step of the way.
That jaw casting design looks a bit iffy to me.
@@paulpaul9914I agree with you, it seems as though he found the problem.
Hey Allistair, I noticed the video says you wear ear plugs all day. If you're using the foam ones you need to look into getting custom fitted ones made to match your ears. They put so much less pressure on your ears/canals. My ears used to hurt and ache from wearing the foam ones all day until I went custom fitted. They block more noise and they hurt a lot less! I can't even imagine how much your body gets broken down doing job like this. I do machine work and it's amazing how sore you can get just standing in front of machines on concrete floors all day. Add to it the raw physical effort you have to put in....Hats off to ya. Recharge your batteries when you can. Looking forward to the second video.
Retired Brit Boilermaker here... I thought I'd done some "heavy engineering", but you've taken the term to many levels above that. I know what you're facing. Holy crap, Batman! And I'm only 8 mins in! I am sooo glad I'm out of the game.
17:35 Not enjoying it, I've had almost similar stress on jobs, with unknown metals... (Typing this as I watch).
22:30 I've had almost 100% success on cast steel using 316L stainless MMA up to around 1". Your analysis is pretty much spot on. Hope you've added a few zero's to the end of the bill for this monster.
Never ceases to amaze the size of the projects you take on
I really have a lot of respect for how serious you take your craft. You may not be an a trained engineer, but you clearly have mastered your craft. It's clear you're knowledgeable, experienced, respectful of others.
Thank you for sharing.
Gives credit to others and doesn't put people down shows your true character and how much a craftsman you are and understand not everything is perfect in the field I enjoy watching and learning
For future reference: If the XRF gun is not available a foundry should have a spectrum analyser you could put a small (25mm x 25mm x 10mm) chunk on to get an idea of the alloy used. (the bench top units deal better with carbon steels)
The amount of force that took to break! God, impressive stuff.
Stressed just watching you. Luckily, those days have gone for me. Stunning work. Stunning work ethic.. You have lucky clients.
Wow, just WOW! I have watched nearly all of your repair videos since you've been uploading them. I am truly inspired by your work ethic. And this one, where you came on in the beginning and expressed your feelings was the best! I understand all too well about these monumental jobs. You see it, and know you're capable of accomplishing it, but the trauma comes by knowing precisely beforehand the amount of mental and physical pain that it will require of you. And I could feel it with you when you spoke at the camera about all the things running through your mind. Your determination and discipline are such a bright, shining inspirational example for anyone, anywhere struggling with anything. Thank you so much for sharing this with us!
Alistair, everything you do on your channel is fantastic and I love it when you’re with your uncle or your father and we have the privilege of hearing about things they have seen and done throughout their lives
I personally think knowledge of this kind is invaluable and should be documented in any way possible….
Huge respect and ❤for you and your family’s dedication and hard work
This one looks a lot better than the last one you fixed. Done and done already
I am surprised that the quarry doesn't have a replacement part to get back to production and have you repair the broken part for a backup when the next one breaks. They already know that they are going to break since you already repaired one. It doesn't matter how expensive the part it since I can guarantee it will cost them more in lost production to not have a spair.
Thank you so much for sharing this type of repair. Not only is it educational but it lets a younger generation see what type of work is out there.
Younger generation not want work like that don't know how things will get repaired after our generation gone
This is a job where I charge a customer to try my best, no guarantee of success. My customers are just happy to find someone willing to take a chance and give it their best shot.
The initial fit up of the two sections was pretty damn impressive. Nice work!
Super cool and down to earth! Thank you for taking the time to show us your work.
Absolute legend thankyou for the support buddy, you guys keep the show on the road!!👍🏻👍🏻
Really appreciate what you do. Awesome channel. Thank you, keep at it.
Wow buddy , I don't know what to say. I don't deserve this I feel I should give some to charity.
Humbled, thankyou very much.
Be sure to call in if u ever this way. All of you guys keep me going, some powerful comments and tokens. Thankyou again
@allistairc123 use this for your channel. I don't know, take the wife out to dinner. Enjoy yourself. With what you do, and how hard you work, you deserve it. Enjoy.
@@allistairc123 you most definitely do! crazy amount of work this. Big respect !
I was a welder for 40 years wore out a lot of grinders I know the feeling in your hands
I've been welding over 35 year's my first thought would be that that couldn't be repaired as you said the thought of that failing as soon as it went back into the crusher that is definitely the difficult of the most difficult jobs you could ever get definitely well done 👏
Excellent fitup. The things that set you apart from the others, is that you are not afraid to take on the big stuff. And you take the time to figure out how to weld it the correct way. Excellent work as always.
Stress is a part of why we do the jobs nobody will touch, keeps you awake at night but alive in the day and enjoying the job, it's the buzz that feeds the fire. Hard graft in every move you make and thinking all the while.
You quoted the list of my welder fabber channels I watch every week and yours is on that list. Thanks for the insight. Cheers
Stress can also kill you, no job is worth sleepless nights, been there, done that, now on 3 tablets a day for the rest of my life, I've seen that look on Alistair's face and the look in his eye's, not worth it if iam honest
You could also be on tablets every day and never done a damn thing in your life, I have seen a lot of it, it's very hard to know what could have been or what might have been. Hope your getting to take it easy now, all the best to you anyway.
Incredible work. I can't imagine how you'll be able to get in around it to weld for hours at a time , not to mention the heat . Big respect
Enjoyed every minute of that! I can only imagine the stress of planning such a massive job with so many variables. Can't wait to see it all put back together. You are an outstanding craftsman...thanks for taking the time to share your work with us amateurs!
What a monster job! Thanks heaps for posting, can’t wait for part 2! You’ve always got some of the best shots of the gouging etc. it feels like I’m standing there with a helmet on.( minus the scalding temperatures) I’d never thought about the stresses on you mentally, I hope your customers appreciate the effort that you’ve going through to get their machine back in service.
It’s always tougher to repair these kind of things that it was to make it and that’s not to say it was easier task, but you don’t know what you’re starting with other flaws and faults and the casting process and the toughest part is you have no crystal ball to predict the outcome I have worked in foundries and fab shops, my whole life you have some amazing skills and I respect the amount of forethought and studying you put into this project before you even started to repair it. Bravo.
Thank you for sharing your time with us. It was a real pleasure to hear your comments on not knocking someone else's work, that happens too frequently and as you say you do not know the situation or the tools they had at hand. Really enjoyed the 55 minutes, it flew past, will be watching your follow up videos and catch up with previous work you have done. Have a great day Sir.
It's just unreal the work thats going into that, Much respect!
Thank you for the videos sir. When the fear suddenly kicks in when you're lying in bed. know the feeling - why didn't I just say no hahaha The owner of the machine is lucky to know you. Looking forward to part 2. All the best hope your Dad and Uncle Drew are doing well
Great video, very good shots of arc gouging at close proximity to the hot end. Thanks for taking the time to put together and produce the video .
Loving this project - I used to be the welding / NDT inspector at the Workington steelworks, west cumbria, so can really appreciate the amount of graft to achieve this kind of repair on very large highly stressed kit - In fabrication this is as tough as it gets
ATB
Dave
I've only done a few repairs on this kimd of scale. I probably would have done an initial test fit, and then welded on some sort of alignment bars on the sides to make sure I got it back together in exactly the same place. I'm amazed it fit up so well considering how much material you hogged off. Awesome job man. These are the kinds of jobs that keep you up at night, but they are also the kind you can be the proudest of when you get them out the door.
Some phenomenal gouging shots in this. What a monster job!
I love this kind of work. I used to do maintenance for a scrap yard; welding, cutting, but nothing compares to the intense w9rk that you do. Kudos and bravo to you. Stay strong!!
Awesome work buddy. Glad that you uploaded again...I have a lot of respect for your labor of love
Masterpiece. Stayed to the end. Fascinated by the process. Always amazes me the scale of these projects. There can't be many places that would take this on. Looking forward to the next phase. I watch Isaac and Curtis. Karen makes top class videos. And her editing work is superb. With Homey security. Their shop is about 2.5 hour drive from my house. I can see why you would stress over this repair. The size and forces involved are colossal. And this being a cast piece. I would have assumed it was junk.
Unbelievable that this could be repaired. Great video explaining the process and stress involved in this job .💪
You are a rare true craftsman that knows what he’s doing and I commend you sir!!!!
Amazing work. An absolute pleasure to watch a master of his craft do a job a lot of people wouldn’t even consider.
Recent subscriber generally more into the tractor content but I found this engineering/welding project really interesting and very much looking forward to seeing part two 👍🏼
The music give you a low-budget 1980's sci-fi movie vibe.
I see the old melted torch is working well...Brilliant to watch true heavy industry at work.. stay safe lads..
I couldn't believe it sat on their straight the very first time you put it on, that was amazing. You're an artist, no doubt.
I've watched a few big machine repairs in Pakistan , I cannot imagine doing that without the aid of modern machinery , even with all the gear your the man .
Mad work 🤯I've spent a lot of time prepping steel for welding with a 9" grinder and I can honestly say that cubitron grinding discs from 3m are something special 👌👌 expensive but Jesus they go good . Keep up the great work look forward to the welding side of it 👍 and good luck 🤞
This was an issue before it came to you to fix! You get to try a second time. Borrowing or renting a spark tester or PMI gun is good. Also, you can buy a mini Brinell hardness tester fairly cheap which can tell you a lot about how hardenable the piece is. Cast is always difficult and how much carbon you are dealing with tells you a lot. You do a very nice job balancing the practical vs the technological. In the end it’s all about did it work and will it last. Finally, you doubt yourself too much! You do awesome work! Sleep well! You got it!
I think the emotions you felt Alistair where quite justified, The amount of stress these jaws go through is incredible, enough to stress even the best of welders out i think, but ive seen your previous work and if any one can its you. Drink plenty buddy.
Refuses to criticize someones field weld and gives props to other guys doing similar stuff. Class act.
The most enjoyable RUclips video I've watched in a long time. As a young fellow welder I have learned a lot, and I know I have way more to learn. Your videos have helped me a ton. Found you shortly after starting a job at a stone quarry in Canada, and I remember my first big welding job. The nerves, lost sleep and thinking there is no way that can be welded and ever hold. Guys at work laugh at me wondering around just looking at a job wondering what I'm doing. I am no where on this scale of repair, but someday I might get asked to do something like this. Keep up the great videos and I love all the details about what you look for and how you learn stuff, very informative and interesting. Cant wait for part 2.
Great video as usual. You are a true master and have the biggest b--s in the industry for taking on a job that size. Can’t wait to see the next episode. Thank you
Raymond 🏴👍👍
WOW that is IMPRESSIVE! You have some serious skill! Curtis too! What you both do is awesome!
I kept looking at the time and thinking man I hope he doesn’t skip the fit up and welding. Very glad to get a part 2 or fingers crossed even a part 3 of this one.
Great video 🤘🏼🤘🏼
I weld for a living & I'm feeling stress just looking at the initial pieces that landed in the workshop. I get your thoughts - that's large...
You tried Pferd grinding discs? They grind..
Takes a big man to take on a giant job like that good on you you've got what it takes no shortcuts great job no fear
Can't wait for second half ,what a huge project .Thanks for sharing
Colossal job and you are a brave man for getting involved - thats a staggering amount of work in Assessment, analysis,calculation, procedure, prep and well what more can be said -I hope the money is worth the stress 😬I know its about the love of the challenge and the job and money is secondary but the stress is like each job takes a bit of you!!!! 🙏🙏🙏🙏👍
I know it adds a layer(s) to interfere with dexterity but wear a pair (or even two) of the orange criss cross gripper gloves. It slows down the onset of grinder numbness for me. Awesome processes, Allistair, love what you do.
You are very brave.....
Very impressive repair, with years of hard won insights and knowledge given away for nothing on this video. Cheers from New Zealand for taking us along with you.
.......G'day,
after 20 years in the Mining industry as a metal worker I can vouch for the noise of those gougers. The boilermakers maxim "cut your way in, weld your way out". Bored? Asleep? Nah mate, love your videos. They show the brutal reality of the forces involved in the process of raw material.
Kind regards,
Malcolm.
Heart like a lion.
They bring it to you - because they know you can do it! Love your videos!!!
I was thinking that at least with this repair you wouldn’t end up “INSIDE” the repair like you were with the car crusher repair….
BUT….
As I watch the video, I can see that you are going to have to be a contortionist….
As always, very nice fit up, can't wait to see part two of this massive undertaking. Take care brother.
One way to secure your bread is to do things that nobody else will do ... and do them well! I get what you explained about the stress, but in truth you'd probably look far and wide for a man who would take over that job and do it better! Thanks for telling the story!
That’s one massive job you got on your hands.
What kind of gloves do you use when you’re grinding? There are anti-vibration gloves to mitigate all the vibrations you’re getting.
Tegera pro 9182 might be good fit for you.
Love Therese kind of videos your posting 🤘
How many AMPS to run those 1/2” carbon rods?
Absolutely incredible. Really like the welding and engineering video's this is the best channel out there. Keep it up!
It is very ironic that my favorite welding/machining follows are yourself and the exact guys that you mentioned. And I found all of you individually over the years. Looking forward to Part II.
Have you tried the 3m Cubitron grind discs, they are very aggressive at material removal, they legitimately save 20% grinding time or more.
They're not cheap but very fast and well worth it when you have a lot if grinding to do.
yes a fantastic difference
pferd discs also good
most of the cheapies just make dust
@@eweunkettles8207 Pferd are hard to get over here in Ireland, If i can't get 3M cubitron I get a Tyrolit disc called Cerabond X which is pretty good too, Tyrolit also have a disc called Rondeller which is really good for millscale.
You’ll have to start charging more money so they won’t bring them to you 😅
Had a contractor who used that to discourage a customer on a job they didn’t want to do , Quoted a figure easily several times more than it was worth . It didn’t work due to their outstanding reputation , the customer approved anyhow , NOW they had to do the job perfectly to justify the price and protect their reputation.
I thoroughly enjoyed this thank you for filming this and editing this jem for us to enjoy. Bloody impressive work ,huge thank-you for this .
I admire your commitment and patience! People dont understand how daunting a taske this can be, i lack the patience to work on one part for months!
Fixing that should be illegal. You know they have the money to buy a new one or pay you to build a whole new one out of AR550 or something beef and easier to fix.
It depends on the lead time of getting the parts, 2 months is quicker than you could get a new part unless you're very lucky.
It’s good to be nervous with a big job, it means you care enough to think it through top to bottom. I wouldn’t want a big project going to a man who didn’t worry. On you go, the path to greatness is one step forward after the other.
Top man! You are some boy! I don't often comment, but having done my share of gouging and welding I appreciate how much hard work and time are in this. Well done!
After the disassemble
and cleaning, after the study and consumable selection. After the surface preparation and line up. You are left with experience, skills and talents. You are a Master of your craft. From a jack of trades and master of none
Definitely not falling asleep watching this!!!
Looking forward to the next part.
Thanks for sharing 🇨🇦
I repaired a small Chinese swing jaw a few years ago. It lasted about 3 months, the same length of time it took for the new bit took to get to us. Your jobs are way bigger than mine. I too hate the grinding. I have enjoyed your videos, you are a real champ
I imagine many times you thought or said, "I'm getting too old for this crap!"
I literally started crying when I heard him say " I hear this noise in my nightmares". Just about fell out of my chair. I'm so sorry for those arms dude.
Hey up mate the filming and workmanship on the gouging was pure art, great video can't wait for part 2
This may be the manliest thing I have ever seen. Great work. Looking forward to the next one.
I am retired now, but was a union construction worker for over 40 years. I cared about my work, and worked hard even at 68 years old. That said, I can see how much you care about the results of your work. My hat is off to you. Thanks.
That's amazing. Looking forward to part 2.