Repairing completely worn out stub shafts in flail mower roller.
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- Опубликовано: 3 июн 2023
- So, in this video I repair both stub shafts in a roller out of a flail mower.
With the shafts been so badly worn, the first job is to dismantle the remains of the bearings to measure the ID. Once the size is determined the old shaft can be removed from the roller end. This is done by arc air gouging the welds away.
Once the old shaft is out, I made the decision to bore the hole out to 40mm so a bigger shaft with a shoulder for the bearing to run against can be fitted. This will stop the roller shifting from side to side causing wear to the shafts.
The new shafts are made in the lathe.
After working out the measurements needed between the shoulders on the shaft, the first shaft is preheated and welded into the roller end.
The roller is then set up on bearings so that it can be rotated to check alignment and to weld. The end is then tacked into positions and aligned to an accepted amount of run out. The root weld was done with the tig welder, mainly just for me to have a practice in a real-world situation but also to get good penetration. The second weld was done with the mig.
After the first end was done, the second end was removed with the arc air gouger and the old shaft was chopped off then drilled and bored through on the lathe.
The same process was then repeated to weld the end on.
Hope you enjoyed the video.
Thanks for watching!
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Kurtis would be proud :)
That was I thinking to.
Yep! 🎉
He'd be even prouder if you used a K
@@AW-Services
I agree with you, it’s Kurtis. No idea who that other fellow is.
Issac is another guy that would be happy with Snow’s efforts.
Some people are good at breaking stuff , you Sir along with Curtis & Isaac are great at fixing stuff and making it better than new in many cases. It's a pleasure to watch & learn, thank you.
I believe that will definitely outlast the machine from the looks of the parts you had to work with. Great repair job, Oliver.
Wow, the roller made my semi-destroyed roller look like almost new. Thanks for the video, very interesting to see.
Gday, the owner definitely got there moneys worth outa that roller, not an easy repair but you nailed it, top job mate, cheers
See you get better as work progress, it looks like the second peace was better than the first.
It looks you watch Cutting Edge And Engineering Australia, I watch it to that's were found you on up next video.
I like your work and your channel well done for the good work.
Curtis done a video showing how to make the rotating earth clamp . Good 👍 job
You have been faster than me.. 😂
Another innovative repair. Even with the labour involved it will still be cheaper than new parts. Cost of farm machinery gone through the roof. Busy time of year, was the farmer waiting outside for it !!
Thank you for sharing, always a pleasure watch your project, I learn a lot 👍👍👍👍
I know the feeling about the work table. You clean it off and after one job its a mess again.. happens all the time to me
I love jobs which challenge. Makes me think of the best way to approach and complete the job. Very nicely done on this roller, it was a mess and really shouldn't have gone that far, but people see what they want to see. Good job, and yes Kurtis from CEE makes some really good kit. Thanks for posting, take care be safe.
Agree
I can tell you that even on brand new flail mowers the roller end shafts are not central to the axis of the roller! On mine, the rollers are around 5mm off axis. Not a big issue you might think, but the scraper bar that is supposed to clean the mud/vegetation off the roller is bolted to the chassis of the mower. This means the gap between roller and scraper bar varies resulting in poor cleaning. The more central you get the roller end shafts the better, so well done for minimising the error. Nice one!
Cracking job Oliver buddy, thanks for sharing 👍
Thanks 👍
Great video! I really enjoy your great ideas to get the job done without all the equipment!
Subscribed from PA in the USA
Thanks for the sub!
No need to justify. Repairing old stuff which has been dragged about working hard over years certainly needs an open mind. You got it done well.
Definitely well worn, AKA "Knackered", farmer must believe grease is possessed!!!!
Great job as always. more work of art, ref lack of existing design, not a criticism.
Thanks for sharing.
That was excellent thinking outside the box with the second shaft. Nice and clean job with the lathe.👍👍👍 Excellent work 👍👍👍 . Thank you for sharing. Take care of yourself 🇨🇦
I agree, I would approach the job using my strengths of machining and welding. This way utilised his strengths of gouging, turning and welding which resulted in a perfectly acceptable job, considering the state it came to him. There's no perfect way, but this was as close as it was needed. 👍 Great comment by you.
Just bought a new flail,,,,hope its a long time before it ends up like that ,,,Vids are spot on mate thanks
Awesome video, great work. Thank you Oliver
Really good repair, awesome job there.
Just some tips for your tig welding: The needle doesn't need to extend that much out. The more it sticks out, the harder it will be for the gas to protect the weld and the needle from oxygen and also keeping the needle cooler. Looks like you burnt your needle, which reduces it's life span. There are some gas lenses, which will suport a longer needle standout, but generally it should be just around 5mm.
Also for the arm you are welding with: It is a really big help to keep it supported. Maybe fix something on the L- profile you used to indicate the new shaft with. Rest your arm on there or on your leg, if needed. The better your arm rest is, the better you keep control of the welding, because the arm and therefore your hand is not that loose. Makes it easier to keep the arc at the welding point and not all around your part. This also ensures better control of your weld, because actually at TIG welding, you should be somewhere around 2mm close to the welding point. That improves the gas' job of keeping the weld free from oxygen.
Thank you for the video.
The customer gave you a real sow’s ear & you made a silk purse out of it.
Thank you Sir
..and yes I do like the Ferrarri sound of your forklift...
good job fixing farm equipment is not alot of fun but you did a remarkable job, I just fixed my flail mower last month all the hammers were worn out. lots of welding I did and the weights have to be with in a half ounce or the mower will bounce every place Kip H Washington state
I'm so glad you gave a shout-out to Kurtis at CEE Australia.
What that guy doesn't know about welding, gouging, line boring, lathe, and mill work is not worth knowing.
I love his show, the diversity of it, even including Karen and their safety inspector, Homie on the act, crazy dog. Everybody is involved.
FYI, that earthing device Kurtis uses he made. Scroll through his playlist, and you will find how he made it. It's so simple, really, and easy for you to make too Oliver.
Brilliant numeracy skills Olly. I'm dyslexic and thank calculators for my maths. Don't apologise for your equipment limitations. We watch because we value your abilities of what you achieve with what you have and not what you don't
You could build quite an effective welding rotator with a DC motor and speed controller, generic RS electronics foot switch and a cheap second hand 3 jaw Chineseium chuck
Great job at fixing something that had been neglected far too long. Where would you be at without your mobile work table aka forklift! Your forklift is like a backhoe we have, there are a 1001 uses for them. Keep up the good work and Be Safe.
I love how you always make it better than it was. ❤❤❤
Respect for your work, you are putting huge effort on each job to be as close as perfect!
I did a Kuhn flail topper last year, exactly the same scenario. After a day of messing around trying to save as much as possible, i ended up binning the lot and starting over. I couldn't get the same size tube so ended up going a fraction smaller, never bothered with the dished end's, just some inch plate on the ends with the stubs welded in both sides. The bearing carrier's were completely goosed so just used some housed bearings and luckily i didn't have to drill any additional holes in the topper for height adjustment.
Really enjoy your videos, see you on the next one.
Turning junk into a almost new roller. You saved the customer lots of money 💰
Excellent thought processes. Great to watch a very skilled man solving important problems. 👍👍👍👏🏻👏🏻😃
With that introduction, I thought Madonna was maybe playing Wetherby and District social club and had popped in for a repair !
I've got a repair to do on our ancient Kvernland disc mower, need to find a short piece of tube or get some 4mm plate rolled. Luckily it's just for pasture topping the nag's field, so no silaging pressure !
Nice work Oliver, It should be easier to keep it maintained with those self aligning bearings. Good brain food are these jobs you take on. They keep the grey matter in good trim. Both you and I will have to make up a rotary earth clamp like Curtis's. Once again, good content and good video composition. Thanks for sharing mate, greatly appreciated.
Well done my friend, another brilliant fabrication and good video 👍
Fantastic that you can get it so close to true. On to the next one.
When I watched this I remembered CEE making one of his earth clamps. Today RUclips put it up as a suggestion and I wondered if you had seen it. I am enjoying your work, its nice to find someone closer to home.
It would be a good idea to include the ruclips.net/video/bIkHtYWENiA/видео.html
Nice work young man.
I like your videos. Great content and filming style.
Olly with TIG you need to help yourself out by propping your torch hand as much as possible to make less tiring and steady your torch so you can keep tighter arc good video mate really enjoyed it thanks
Thanks for the advice 👍🏻
looks like the way my neighbour's broken hip was repaired lol
Ery funny intro....the best to you and yours'. Keep them lessons coming.
Amazing work and great videos, keep them up
I really like how you solve problems
Very well and carefully done.
Excellent job.
Curtis made the rotational earth connection himself. I think he made a video showing how it was made.
Well done you ! Ever the able improviser !
Great job mate
20.58 That's a tidy bench in my book . Great work sir ,your repair work takes me back when my father worked a farm ,we were always repairing something 😂😂👍👍. 27.45 If you're learning tips from Kurtis at Cutting Edge Engineering you wont go far wrong ,your type of work has a lot incomon .
Mint job olly a lot more to think about on that roller then first meet,s the eye. Especially to get it so accurate. I suppose a little bit out on a long roller is surprising some times. Makes you think it pays to check all the time. As you do. Reminds me of Pakistani truck when they do axle repairs on you tube. Similar thing. Thanks Ruth 😁❤
Great problem solving
excellent and perfect work.
Very nice job !!
Really nice Works. 👍 Thanks for sharing.
It's nice to see you doing some tig, last year I bought a second hand tig off ebay and only just got round to getting a torch and gas for it, I have never tigged before but tried last weekend and i cant tig weld at all lol i just seem to mess the electrode tip up almost instantly so I have lots of practicing and learning to do.
Excellent job man, great video, keep'um coming..
Great Job!
Great wrok as always.👏👏
Tricky job done well thanks.
Nice job Snowy, IME theres always more work in those jobs than you first think
More than the customer thinks or wants to pay for. They just want something cobbled together & put back to work.
If they really cared they wouldn’t have let get into this condition.
Thank you for the video. Thank you Sir
Pretty darn good for not having all the right equipment, I can only imagine what you could do it. Great work mate
Good job, just a thought, if you tack 3 strips on roller might be easier to center end cap,i know that you know what you are doing, I enjoy your work!
great video!
Nice melty welds!
Difficult job getting it disassembled, that was operated well beyond its serviceable life . I hope you are well compensated for your talents in needing to reverse engineer then recreate the parts in a superior design.
People like him live for that kind of challenge. His life would be boring otherwise
you sir are to good for your age thanks.
Nice one!
Thanks
Hi a Dial reading of 1.00 mm TIR ( total indicator reading ) only puts the centre off by half ( 0.50mm ). So no problem. Great videos.
Hi came over from WWW recommendation, great channel !!!
Thanks for coming
I would hope this farmer now understands it would have been quicker, cheaper and easier to change the bearings. Maintenance is a unknown concept to some.
This car has everything to do a clean job, beautiful to see, with the right tools, and just does a trick all the time. something that is supposed to be done in an hour takes all day. 🤦🤦🤦😡
You should see the Keith Rucker video on the rotary welding table he got. Yep. Burned out a cheap toggle switch right away. But it has an arm to hold your mig gun so its set the gun . Weld a circle. Move the adjustment and weld another circle.
Awesome job,
The kiwi
On of the channels I saw a guy turning a pipe much longer than his lathe: he had rollers on the back end supporting the pipe and he welded an extra piece on the other side that went into the 4 yaw: adjust the 4 yaw to the pipe close to the chuck and turn the diameter for the bearing. Turn around and rinse and repeat
Hard life for those bearings 😢 maybe the roller wasn’t running true 🤔 definitely needs a stronger repair 👌🏼
Great video
☹🇬🇧
I think the roller will be worn out before they need new bearings. Job well done 👍
👌👍
I was going to ask if you watch Kurtis. That would be a yes. 🤠
I have used normal rods abd gravity to cut up to about 1/8" sheet, just crank the current up to 100! 400 amps plus air must be Hot! Because 225-250 was like getting in tge suns face!
👍
Great video, as usual, can i ask what wire did you use for welding E19 steel, thanks
Old Roman saying mate: "Pulmentum expandet ad implendum spatium" (The mess will expand to fill the available space)... And it does it when you're not looking. Another workshop fact is that the spanner you just put down will never be where you just put it.
The bearings stay put much better when the scraper is kept tight: it holds the two ends of the machine together. I double nutted the bolts that hold it on on our machine.
Satisfying job. Would you not want the end of the lathe further away from that wall, so you can put long pieces back through the spindle nose?
I cut a hole in the wall 😆
Nutter!@@snowballengineering
What’s the advantage of arc gouging over oxy/acetylene torch, is it just more accurate?
Another great video btw
Easier and faster. It melts the metal away instantly
I was about to suggest using the lathe to bore out the shaft remnants, then I saw the second half..
USA tiền tiền bạc nhất OK number one
Whatever you are billing, add 20%
When I see you gouging it I think why no put that cap in the milling machine :) but good work mate.
Same happened to my flail mower , i left the roller off !
What amps do you require to burn 6 mm carbon rods?
08:05 "Fookin' 'ell!"
Juvenile jokes of the bat😂😂😂
Think You need a sandblaster to clean things up.
Those bearings were shot. Probably with a rocket launcher.
I was surprised to not have seen any grease fittings on the old bearings. Did I miss them? Without grease to keep the dirt out such bearings are made to fail.
Yes, they do have a grease nipple on them. Self aligning bearings are terrible for accepting grease though. A lot of the time the grease comes out between the housing and bearing rather than actually going into the bearing.
Where is the "air" bit of arc air gouging? I thought air ran down the inside of the rods but they're solid and there's no way to make an air connection to them?
The air comes out of 3 holes on one of the jaws that holds the rod. So it’s blasting air down the outside of the rod. The main cable that comes out the hand piece has the air hose and power cable inside it that you connect up at the other end.
That was a slow, expensive weld on that roller end lol. Mig my boy.
Got to get some tig practice in somehow 😆
In this case, wouldn't it have been more economic to purchase the end of the roller complete with stubshaft, and then fabricate the end plates? I do admire your work and this is not intended to ba critisism, (sorry can't spell).
Possibly, I don’t know if you can purchase just the ends.
@@snowballengineering Yes, I agree your solution is probably better than a Replacement part, however i have a Major 5m finishing mower and a complete roller last year was £730.00 which was faster and cheaper than getting the ends (stub shafts with bearings) repaired, (I had damaged the big socket head screws holding the ends) therefore replair was going to be > £1000