Repairs to the Bantam C35 Dragline Crane - Replacing the Sprockets - Machining, Welding, Shrink Fit
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- เผยแพร่เมื่อ 6 ต.ค. 2023
- This video is dedicated to the memory of an amazing friend and mentor, Ron Erickson. You taught me many valuable skills and put up with my questions for the last 25 years. I will always have fond memories of our time together in the electrical cabinets of EMD locomotives. Rest in peace Ron.
***Obituary***
Ronald Gordon Erickson, 81 of Clermont, FL, passed away peacefully on Monday, September 25, 2023 after battling Parkinson’s for over 7 years.
Ronald was born on June 10, 1942, to Gordon and Elsie Erickson in St. Paul, MN. He is survived by his siblings, Janet (Donald) and David (Pu); nephews Neal (Cynthia), Keven (Krystyna); niece Amica; and great niece Charlie.
Ron was hired at The Great Northern Railroad in March 1962. He attended Dunwoody Institute and acquired his Electrician License in April 1967 through the Railroad. He worked his way up to Superintendent and spent as much time riding trains and troubleshooting as he did in the office. He continued his employment as it transitioned into the Burlington Northern Railroad. He chose to go back to the shops in the 1980’s instead of relocating his family to Kansas. Following that, he worked for the North Shore Scenic Railroad in Duluth, MN and then was hired and worked at the Mesabi Railroad, also in northern Minnesota, from where he retired.
Ron met Ila Johnson at Glacier National Park in 1962 where they both worked for the summer. They married on February 15, 1964. Ron and Ila had three children, Lisa (Steven), Andrew (Brenda), and Steven (Steven); and granddaughters Shannon, Hannah, Karlee, and Kenzie, and step-great granddaughter Makena.
They moved with Lisa, as a baby, with a railroad job transfer to Whitefish, MT in 1967 but a year later they were back in MN. They raised their children in St. Paul, MN and then moved out to the suburbs of N.St. Paul, MN where they built a home designed by his father, Gordon.
In July 1998, Ron retired and spent his time model railroading and working on his property where they had built a beautiful log home on the stunning shore of Lake Superior, near Two Harbors, MN. He continued to consult his passion with museums and various train operations and to assist anyone in need of air brake troubleshooting. They moved back closer to the Twin Cities in 1996 to Bethel, MN where they lived in a beautiful home on seven acres with a pole barn; perfect for accommodating his MC Crawler, Bobcats, sawmill, workshop and HO train set up where he always said “I don’t know when I had time to work!”
Ron was predeceased by his parents, Baby Girl Erickson, and beloved wife, Ila Erickson in 2020. After Ila’s passing, he spent his last few years in Florida with his daughter but was always a Minnesotan at heart and truly missed the winters!
******
I want to thank Lisa(Ron's Daughter) for helping me put this dedication together. And, for taking him in for his final years and allowing him to pass comfortably among family. You gave him the best final years anyone could hope for. Thank you.
In this video, I finally get to fix the biggest problem with the Bantam C35 Dragline Crane. The main sprockets were completely wore out. In fact, one only had 3 teeth left when I bought it, and we took them out unloading from the semi.
Watch as I come up with a solution, and execute it. With the lathe work of both pieces, then a shrink fit, and finally TIG welding the sprocket on. This repair is sure to last my lifetime.
Topper Machine LLC is an entirely manual machine shop located in Spooner, WI. Our videos will highlight some of our shop work.
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#machineshop #machinistlife #manualmachinist #mobilecrane #crane #repair - แนวปฏิบัติและการใช้ชีวิต
A fitting tribute to your friend. Thanks for sharing the obituary. My offer on LN2 stands, if you ever need it. That said - man I kind of want a dry ice set up now. That's a really nice repair job - I think it's great for people to see what kinds of things can be done to keep machinery going - with ingenuity, determination and skill a lot of things can be saved. Repair culture beats throwaway culture every time. Cheers and best wishes as always.
Ron is definitely missed. We had a good 25 years of troubleshooting and repairing locomotives. LN2 would be nice sometimes, but the dry ice has never really let me down. Still, it's amazing how disconnected my region is from the rest of the world when it comes to getting supplies. You either become self sufficient, or you fail.
True all round. The LN2 doesn't get you very much further than the dry ice in practical terms, and the dry ice is a lot easier and cheaper. It's nuts how little support you get for where you are - seems like a lot of dealers and suppliers just don't want to go to the trouble of going very far out of the metro areas. If I was smart I'd come up with some kind of business opportunity around that.
@@StuartsShed when you come for a visit, you will see just how desolate this region is. It's really sad.
@@TopperMachineLLC In same situation where I am. Thanks to Ebay and Amazon I get what I need. Without them I might be out of business.
@@kmcwhq eBay or drive hours away. Bigger problem is that the local govt wants to keep this region depressed. They drive away industry and progress. I have never found another region of this country like this one.
We are all part of something far greater than ourselves. Sometimes that part is named Ron. We all thank you Ron, for bringing Josh to us !
Thank you. Very well said. He helped shape me, and built my knowledge of so much. He is deeply missed. 😪
I bet your shop smells just like old model steam train smoke... ah! Loving the lathe work. As a woodworker with a small lathe, I've gotten some great ideas from you dealing with quill and jaws.
Beautiful work as always Josh, I am sure Ron is looking down and commenting to himself on his pride in your work. Best regards Sarah
Always fascinating to see the work that you do - and do it so well. A wonderful tribute to your friend and mentor Ron. How many of us take the time to recognise the contributions of colleagues and friends to our lives? Too few of us I think, until it's too late? I know that I have....
Outstanding work today Josh. You really scored on eBay with those gears and that drill! The chip’s coming off that bit were some of the cleanest, thickest chips I have ever seen from an operation like that. Lovely episode! 😃👍
Thank you.
Hey John, nice to see you here!
Hi Josh: Ditto's to Sara's comment. I do enjoy you work. Always very thoughtful. You plan your jobs from start to finish before actually doing the work. This way the job turns out as expected. I can see that you have much experiance in what you do. Wnderful work!!
Thanks. Yes, lots of planning. Sometimes it doesn't go as planned, but that is where experience takes over.
ZI have seen track plates and sprockets in a similar state, I worked with a British company called Ruston Bucyrus (now gone and forgotten), the parent company was Bucyrus Erie, the trak gear was similar to your layout. The machines always seemed to last forever, till they stopped.
Thanks mate watching from Australia
Great video...I have loved watching this channel develop. You are an amazing machinist and great teacher. I am lucky to know you.
Nice job, love the shop made dry ice, very useful to know Josh.
Some healthy swarf there 👍.
Thanks for sharing
When I was stationed on Iwo Jima in 1955 we cooled a tub full of Japanese beer with a C0-2 fire extinguisher.
"Because, who doesn’t like explosions…" I friggin love this channel.
That eBay twist drill did a good job. Thanks for another excellent video. 😊
Thank you. Thoroughly enjoyed this practical engineering. This is a lovely dedication to a mentor you held in high esteem. This video was so real that I swear I could smell the oil burning off!
Thank you very much.
Fun project! Glad to see interesting videos like this 🎉
I wouldn't say this was fun, more necessary to move forward. Actually the machining part was fun, none of the tear down and reassembly. Lol
Still very cool to see you put in the effort to tackle a job that almost no normal guy working on old machines can do. It’s a part that’s impossible to buy and can only be made. People just don’t do that, they don’t have the knowledge, capabilities, or ambition.
These type of videos are my favorite for sure !!!
@@redmorphius I'll be honest with you. If I didn't own a machine shop, id never have bought the toys I have. Sure, I could take the parts to someone to have made, but who can afford that. Even when it comes to my steam engine, one of my best friends owns a boiler shop. If it weren't for that, I may not own a steam engine.
Haha yep. Having a machine shop is enabling to the things I drag home too lol
Cool project. Hope to see more vids on its resurrection
Rest in Peace Ron Erickson, may your memory always be a blessing.
I worked for Martin Sprocket & Gear for many years operating many different machines.
8:35 - Pretty equal chips off both flutes.
16:50 - At Cinti Mill, we'd toss dry ice into an alcohol bath, and then bathe the part; got to every bit of the part.
18:59 - 6-thou sounded like a 'healthy' shrink fit; I use .001" per inch of diameter.
21:40 - Pretty rare I'd use anything other than TIG; the temp control is wonderful.
Nice repair job.
Hello Josh, once again a great job. I wonna see more of them. :-) Dieter from Germany
Thank you. More cool stuff to come.
Another top quality video from the TOPPER machine shop. Good old fashioned machining not a computer insight. Thanks for taking the time to produce
Another great job!!
Nitemare repairs make the best videos!
I would agree, except when you can't even get the camera in there. I would have filmed the reassembly if there was room for the gear.
It was a pleasure to meet up with you. The trip was great, and good luck with your crane project. Keep me posted on your progress...
Good stuff Josh
Sweet! -Doozer
Who doesn't love a machining channel that does actual machining! Well done Josh!
Not to many of us out there any more.
@TopperMachineLLC It's very refreshing to see. I know how much faster and easier it is to do a job without filming it, and then editing it, but the effort is so valuable to many of us, way beyond the entertainment side of it. I learn a lot from you. Thank you!
good job you are awesome......
Thank you so much 😀
Nice repair job. It's sad when older friends pass. I had several older friends 20-30 years ago, they have all been gone for years. I recall the times we had together and projects we worked on on a regular basis.
That was a LOT of runout on the original sprockets. Those new ones are going to run smoother than the originals ever did.
Thanks! For the awesome content. Can’t get much shop time anymore and appreciate your videos!
Thank you so very much. Its Greatly Appreciated !!!
The hardest working man in Spooner strikes again !
Nice work Josh.
"LIKE" button has been torqued to the manufacturer's recommended specification. "CLICK".
God forbid you should be running around Wisconsin there with a loose "LIKE" button and winter closing in !
Great job there. I wonder what metal would not shrink. Thanks for the video keep on keeping on.
I was wondering if it wouldn't shrink because of the shape. Being a tube, there isn't a solid piece of internal stresses. That's just my guess. It did shrink, but only 0.001. Definitely not enough.
@@TopperMachineLLC I used to shrink motorcycle cylinder sleeves and they are round. It must be the metal. Maybe someone will experiment to satisfy my curiosity.
Sorry to hear that you've lost another friend. It's very sad losing friends. Condolences to all.
Thank you. Been a rough month here for sure.
A very nice dedication to your friend. I can imagine him smiling.
I'm sure he is. He watched my videos right up to the end. Just knowing he was watching and enjoying my content meant the world to me.
Enjoyable viewing "putt'in the newness back" 👍🏻
I have been looking forward to work starting on the old crane.
Thanks
This was the first of the repairs, and the worst part. Next is track rollers, new track pins and pad repair. But that will be a way out. Hoping to be moving and digging by next summer. But we will see how bad winter is. I have to work on this stuff outside.
Great work buddy, RFT, Right first Time👌
Wonderful video thank you for sharing everything with us buddy I love watching
You always make it look easy! Sorry for the loss of your friend.
Good morning Mr. Topper from San Rafael Bay CA. Your dedication made me tear, what a really nice person you are. A Class Act of skills and Heart.
I like your "DRY ICE '' set up, I remember using the freezer at work to do a press fit of "Duramax Industrial / Marine, Cutlass Rubber Bearings. after "freezing" out of the refrigerator to the assembly area and load straight in the Cutless Bearing into a very expensive lost wax cast 316 SS body frame and machined, then using a "Dake Press" with NSF approved lubricant, press in while watching the hydraulic pressure if going high stop! Yes we lost many bearings and added expense outside machine shop removal of a stuck bearing !
I had made a lot of the procedures to do all this, we even did what you did and chamfered the leading edges .
You might like these 'Bearings. We used the ones with 316ss and the rubber bearing surface was NSF approved for drinking water.
We used this bearing in centering the shaft to the "LiLLY impeller for high speed industrial potable water tank mixing, the system was used to prevent water stratification temperature bands and to lower chloramine production due to Cl2 injection for disinfection and ammonia also metered injection as pH control in Drinking water.
NOTE I am not a sales rep for "Cutlass Bearings" yet it is a very good prduct.
Great work Mr. Topper Take care.
Kristy
Thank you for another great video showing how simple things can be repaired.
Sorry about the loss of your friend. That pick of him besides the engine with the hand holes tells me he is wood good stuff. :-) I always keep a big hammer in hand to rapidly send a part home when doing a shrink fit cus if it sticks you know how bad it can get! lol
The pic of Ron is actually working on the starters. A major failure and frustration point on these engine
The TH-cam algorithm brought your channel to my attention. I subscribed. Looking forward to binging on your videos. I can tell I will be learning a massive amount.
Welcome aboard!
them nice big chips off that drill
My heartrate went up when you dropped that first sprocket on, and like you did a big sih of relieve when it dropped,
You should have been here, you could feel the stress in the air. Lol
"Nightmare" work is the most fun to watch. =P
Yes, but the hardest to set up and film. I really have no idea how we would have shot that.
Awesome job Josh.
That drill bit you got really cut pretty good.
This job is probably better than factory.
Pretty cool making the dry ice.👍👍
Have a great day.
Hi it looks like you need to be wearing some armour for protective clothing there looks like you’re having some fun Hooroo Paul from Australia 🇦🇺🍻👍
Those chips are heavy and hot. Like being shot with a shotgun. Stand back and watch the show. Lol
Top, I really enjoy watching you work. Your machining skills and equipment are awesome! I love how you can clean up broken parts and machine parts from stock material. THANKS FOR POSTING!!
Absolutely BEAUTIFUL work!!!
Thank you
Real craftmanship is the keystone to quality
hello john it's is randy and i like yours video is cool thanks john friends randy and i am enjoy yours video is cool thanks john friends randy
That was neat. Thanks for sharing.
This was a cool project and it turned out great. It will be good to see the crane mobile
I can't wait to drive it around. Getting tired of pulling and pushing it where I need it. It's kind of heavy. LOL
Shrink fitting reminds me of an incident that happened to me decades ago. I had a load on my ute (small pickup truck here in Australia) and one of the axles came out resulting in no brakes and no gears to slow down. The reason: Someone had replaced the axle bearing and hammered the retainer on instead of shrink fitting it. Lucky I was close to home and I had a spare axle on hand. I've replaced a few axle bearings and I always shrink fitted a new retainer on and I never had any issues. You simply heat the retainer up until it turns blue and drop it on and let it cool.
Man, you got lucky. I've had similar happen to me and people I know. Can end badly.
Great shot of you through the oil smoke….
Well done
Excellent video. One of your best yet! I must take exception with heating the sprockets though. Direct heat will ruin any hardness. Put them in a pan of oil, heat it to exactly 250°. put a piece of scrap or other material in the bottom of the pan to keep the sprocket, gear or bearing being heated from contact with the bottom of the pan. Yeah, yeah, I know. You are the expert and experts don't take constructive criticism.
Good suggestion. I've done this exact process many times and wondered if there was a better way. Never had one wear out quicker doing it my way, I don't ever go that hot, and heat super slowly. The 350F I brought it up to was done over 45 minutes.
Should have her up and running in no time at this rate.👍👍
She runs great. Just the drive side needs attention. Hopefully this coming summer she will be on nearly new legs.
Good to see ya back, Josh.
Hey Josh. Great channel. Good work! What are your plans with the dragline? Be well. Cheers. David
Josh, wonderful......
It is interesting to see how the boys with the big gear do their order of operations. They invariably do the exterior work first then bore to match. Me with my little hobby lathe, the weakest link in my system is definitely boring. I would never dare turn an exterior diameter then try and bore to match it. The movement and flex in small boring bars means they are a raffle at best for precision, for me its all about getting a consistent internal diameter close to what I need, then matching the exterior diameter to what I have achieved internally.
Most hobby machines are too flimsy to do the work, but they are great teaching tools. When you get a chance to run real machines with good tooling, you should be able to do great work.
Sorry for your loss.
Josh, it's not that it's irreplaceable, it's just more time to make it then you have! 😂
That is 100% it. Not enough time between paying jobs for hobbies.
Sorry for your loss Josh. great work, I had a shrink fit go real bad one time. I will never forget it. I am always ready with plan b and plan c as backups .. everything ready to go in case.
Always nerve wracking. I've also had one go horribly wrong.
Great repair. That heavy smokey drilling was so realistic I could almost smell the hot burning cutting oil.
I’ve never seen a direct reading bore gage like the one you used.
Starrett 823 inside micrometer
I looked up the Starrett 823 and understand it now. You set the gage smaller with a mike and read the larger diameter off the barrel.
Just found your channel.
Very skilled work Sir! Also, very clear and watchable video.
You have a new subscriber.
Good video Josh. Always enjoy watching press-fit sprocket installs and the associated stress :)
Always a lot of stress, but it's also fun.
I like your. dry ice rig - very ingenious. Great project.
It's all about necessity. I don't have many options for supplies here, so I have to make solutions.
Great Work This
Amazing work
Josh,
Great job....the Lion handled the interrupted cuts like a champ...and yes i agree shrink fits of ANY type are nail biters......LOL.....major rains here..so far since 7p last night to 10a this morning 3.85 inches of rain.........glug glug glug
Don
Wow. That's crazy. We are catching up on moisture finally too. Pond is back to normal level.
Very awesome Josh
A good job well done!
Good stuff
Excellent work Josh, Shrink fit jobs always get me nervous. About the time I have it figured out and getting close to my finished dimension I start second guessing myself. It usually works out fine but it can make a guy sweat. The worst would be having the parts stick when they are not fully together. I really enjoy the channel. Thanks
I've had them stick half way before. Man, that sucks. Bore it out and start over.
Nice job again Josh. I have not shrunk anything on for a good number of years now, but I always got myself prepared. Have everything at a good working height, have everything you might need close to hand, so you are not looking for it. Use a large copper or brass plate to put over the item in case it needs tapping with a hammer, which is close to hand, use a tube if its a bearing going on, that is a neat fit to the race. Lastly, have a much bigger hammer, just in case!
I stayed about an hour south of where you are many years ago, for Christmas and New Year in Eau Claire. My friend had a couple of years lecturing on a type of scholarship from the UK at the university campus there. I seem to recall the temperature dropping to -40C on the bridge over the river. I can imagine that it would be hard to get what you need easily there. I'm lucky were I live in West Yorkshire, there is still a lot of manufacturing here. Colchester lathes, Mitutoyo and others are only a couple miles away. I picked up a new QCTP and holders last week, I was back home in 40 minutes.
Shrink fits are always nerve wracking. I would love to have more things readily available, but then there would be way more people around. I guess I'll stick with less people and less supplies.
If you were able to seal the tube and put some coolant in the dry ice , I think you would probably get a better result.
The heat or cold conduction between the steel and powder would be very low.
Adding a liquid would improve it by a significant amount.
I considered that. Isopropyl alcohol would have helped.
Really neat trick with Co2 and dry ice! I;m curious though, what did you use for the bag?
That was an interesting repair and well thought out how you did it. You made a nice smoke screen with the oil. I thought you would have used the Anchorlube, but probably too hard to get it into the cut.
I considered the volume I would need and the delivery system and went with the oil. I'm still learning all I can do with anchorlube, but it's very impressive
nice video we used too make sea mines of dry ice that was a show
Man, that would be fun to see.
Would a parting tool, set up in a boring configuration not be faster to remove (cut behind) the interrupted segments?
Need some anchorlube smokeless on that drill
Since this video was shot, I've switched to anchorlube almost exclusively. It's very impressive stuff.
That bit may not have looked to be ground nice but it sure appeared to cut well.
I was pleasantly surprised by how it cut.
Ok, so my untrained approach to those gears would be to cut em off with a thinner cutter from the front so they come off in one piece(just inside the depth of the teeth). Seems like it would be less likely to break the cutter (i break everything I use usually, so I'm paranoid about that) and maybe faster? But I'm not sure that's proper form, how that would destroy tools, or whatever. I'm not a machinist, but I'd like to get a Bridgeport for gunsmithing use. Cutting metal is cool.
Shrink fitting always has a pucker factor! A note on Anchorlube...i bought some as ive never used it before. Did some testing with it and as i am a woodturner as well i have stuff called Anchor Seal for sealing green wood ends to help in cracking...its exactly the same and wayyy less expensive! Rockler has gallons of their green wood end sealer. Same as anchorlube but white and doesnt smell like almonds! Its all emulsified wax product...cuts and taps the same. FYI in case anyone wants to try it out.
Sometimes if we put too much interference fit on something.... It makes it weaker....... Look what happens to a lug nut.... If we if we torque those lug nuts too tight.... To where they are on the verge of 11:31 breaking...... What if truck had a heavy load on it and you went around the corner.... Those lug nuts are going to get an ungodly amount of pressure put on them.... So you pre-loaded them.... If you over torqued them....
A general rule of thumb for shrink fits is 0.002 for each inch or diameter. I was under that by a few thou. Nothing to worry about with this repair.
Looks like you used a Prime Weld TIG welding machine. How do you like it?
Love it. Only regret was not buying it sooner.
Hi .
One of those trepanning boring tools would cut quickly below the sprocket teeth and save you a lot of slow turning.
Not worth having tooling like that for one or 2 parts.
@@TopperMachineLLC I've only been watching your channel for a few months, but you could have used one on at least 3 projects.
@@oldschool1993 but if I had one, it's really only good for one size. So I'd have to have more. It's more about the cost than it is about not wanting a tool. I'd rather put an extra few hundred in my pocket than buy a tool for one job.
How come I haven’t seen anybody ever try to make a sprocket? It has to be possible, no? I keep saying I’m gonna make one some day for the go karts but I haven’t tried it yet. I haven’t thought it out yet. I’m just a hobbiest machinist. I make a whole gear set for my old South Bend. I bet if you did a video on that it would get a lot of views because like I said there are no videos on it at least I haven’t found any. Btw I love that Monarch and Lion! I have a 13x40 Clausing and love it!
A shop I worked in years ago, needed some sprockets for a parts order. They were backordered 3 months. We made 4 of them. When it was figured out how much they cost each to make vs buy, we lost a lot of money. But then again, without the sprockets, we could have lost way more on canceled orders. In my repair, a $100 sprocket was worth every penny vs the hours lost making them. Not to mention the heat treating that needs to be done also.
@@TopperMachineLLC I totally understand that. For me it was all about the fun of doing it. I guess I would have to use my rotary table to do it? I’m not really sure. Or can I just do it in the indexer? Actually for the go karts I think there was a size I couldn’t get. I have to think about that
This old tony did one.
Joe
@@stacy6014 did he? Somehow I missed that one
Are you using used motor oil as cutting oil?
No, it's just that filthy from use.
Didn't film the reassembly because you had to use all your "special words" to make it go back together? That was a pretty slick piece of work!
Special words, lol. It is also really tight quarters under there. Flashlight in my mouth, and contorting into unimaginable positions, just to use your fingertips to tighten bolts you cant see. Yup, it was fun. Lol
The entire process was interesting. I do not have your skills but I understand as you explain each step. I know that it takes a lot of time to get things set up right. It is hard to get supplies up here. Yes, it fun to blow things up. Those parts are so heavy and it is cool how you were able to make the parts work. I am glad that you got this done before it got cold out. Good friends are hard to find and I am glad that you and Ron were good friends. You did a great job on the video. It is always good to see.
I'm not a machinists but why not trepan the gears off? Wouldn't that be easier on the lathe and tooling?
You look like you could use the Monarch about a foot higher, you're gonna get a sore back bending over like that! lol
Doesn't bother me
Someone should mention,if the chain is worn ,stretched, the pitch will change and the sprockets will wearout again.
Chains are being replaced with new ones. Fixed right the first time.
Could you machine from the end just past the teeth with a button insert rather than dealing with the interrupted cut? A question, not a criticism.
I've never tried it, but I doubt it.
Possibly a heavy trepanning tool but it wouldn’t be worth it for just two parts.
@@ellieprice363 trepanning has its place, but usually not for my quantities
Ah. It just seems like interrupted cuts are certainly hard on the tools and perhaps the work or the machine.
@@The_DuMont_Network sounds way worse than it really is.
Might be worth investing in a dewar and getting liquid nitrogen for these kinds of jobs. I can fill my 30L dewar for less than the cost of an 80cf CO2 refill without having to worry about hydro testing fees. Definitely beats the days of using dry ice and acetone.
Unfortunately it is not readily available here. This is the most remote and depressed region of the world.
@@TopperMachineLLCI'm in the same boat, but my welding gas supplier fills them without problem, other than driving an hour to get to them it's as easy as any other transaction with them.
I should say, I live in the middle of nowhere MN between three reservations. It don't get much more bumfuck than this short of wyoming.
@@ForfeMac I've asked, it must be shipped in. Not really worth the hassle for something I do once in a while.