Cast Iron Repair

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This is part of an exhaust manifold off of a large CAT generator.  It was cracked in the crotch of the “Y”.  We ground out the crack to the full depth of the material then started welding the crack back up.

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The repair was completed to the satisfaction of our customer and no leaks were reported.  We do not have  an oven so this cast iron was welded slowly and in a way that protected the piece from over heating.

Excavator Bucket Repair

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The wear plates on this bucket were obviously worn.  The way the wear bars were installed from the factory was not the best way.  When the bars are installed parallel with the flow of the material they do not protect bucket well.

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We removed the damaged wear bars and installed new wear bars perpendicular to the flow of material.  The reason this configuration is better is the dirt (in this case) will get caught between the the bars and protect the bucket bottom.  The material then is wearing against the hardened wear bars and dirt.

Aluminum Bar Stool Repair

A local high end outdoor living retail store contacted us about repairing a piece of furniture they sold a couple of years ago.  The manufacture would not warranty the piece any more.

Aluminum bar stool pieces

The aluminum bar stool came to us in four pieces.

Aluminum Bar Stool in one piece

We were able to put it back together for less then half the cost of a new piece.

This opened the door to a new customer, the outdoor furniture store has since sent us a couple of other small aluminum repair projects.  This is the way we grow, satisfying one customer at a time.

Bronze place marker repaired

We do quite a bit of work for a local cemetery, from working on their trailers to mowers.  This is a bronze place marker for one of the graves.  While mowing the lawns they drive over these place markers and eventually break off the bolt attachment.

all threads welded back on bronze place marker

Typically the heat from the welding would discolor the top side.  We remedy that by using several wet rags as a heat sink and put small stitch welds a little at a time on each all thread in rotation.

We used an aluminum bronze welding wire .035 diameter and straight Argon as the shielding gas.

Water Tower Repair

We were called out by a Fire Prevention Company to repair some holes in a water tower.  Interestingly enough, they found us on the Google search.

They didn’t want a sprinkler tank any more

Several of the holes Dan was able to patch using one patch, however there were many which required one hole one patch.

several patches

It is always nice to work for a new company and have the opportunity to build a new relationship.  Once they put some paint on this tank it would be difficult to see the repairs without standing right next to it.

Dan used E6010 welding rod which is used in many different applications including gas line and water lines.  It is a nice rod to use when welding on thin material.  The patches are  10 gauge sheet metal which is the approximate thickness of the tank walls.  10 gauge is nearly as thick as 1/8 inch.

Bronze Casting Welding

Recently I welded several Tee Marker Signs at a local Municipal Golf course.  Their challenge was they believed the bronze tee marker signs were being stolen.

The signs were made from a bronze casting and were very expensive to replace.

Bronze cannot be welded with steel welding wire, thankfully I had the appropriate wire.

I drove around the course and welded every sign.   No, I did not get hit by any golf balls.

Excavator bucket repair in Santa Cruz

I repaired this “Remu” type excavator bucket for BlueIron, Inc.  They had a job in Santa Cruz so I traveled there to work on the bucket.

The blade was obviously worn,

I cut it off and replaced with a new one.

The grinders were also worn and I hardfaced using tungsten powder.

Hardfacing is the overlaying of a harder material than the parent metal to help the existing metal last longer.  There are several types of hardfacing.  Some are designed to withstand abrasion which you would use in an application where the piece was subject to constant wear from dirt, sand, or gravel, etc.  Others are designed for impact resistance which would be used in applications where the piece is used in crushing or chipping.  The product I used is designed for high wear applications, it is a very specialized type of hardfacing and provides for excellent wearability.

Gate Repair in Sacramento

I was called out to an apartment complex on the north side of  Sacramento, they stated their drive thru gate had been damaged.

This gate had apparently been damaged because someone backed into it.

The only piece that was damaged was the 2×2 frame.

I cut out the full vertical piece of the frame and replaced it.

Then sprayed primer so it did not rust and made it ready for their maintenance to paint to match the existing.

I was on site no more than 45 minutes.  A nice little job.

Broken Fork on Forklift

A Front Loader Fork lift had a broken fork.  Some folks say they don’t have much luck with welding the fork on  a forklift back together.  I do my best to not depend on “luck” to determine what I can or cannot do.  There is a specific procedure to weld these together.  First you must make certain the forks are parellel and they are lined up right.

Then preheat the forks to ensure the weld does not cool down too quickly as the forks are being welded.  It is critical that the filler rod is tougher than E7018 because the forks are typically a medium carbon steel and tougher than mild steel, I used E10018.

Here I used the back of my truck to align the forks, as if the truck needed the additional weight on it, it held up alright.

Modified Gate for Security

 

I was called out to Amtrak here in Sacramento, CA to modify luggage enclosure gate so folks could not reach through or around to open the door.  I used 1/2″ x #13 flat expanded metal for the screen and 1/4″ round bar on the top of the screen so there is a smooth surface on top of the screen.

The gate on the right is a rolling gate and the one on the left is a man gate.  We have been out to the Amtrak station several times to modify things and they have always been nice and good to work with.

This modification is similar to those we have done on pool gates for Apartment complexes, Hotels, and Motels.