Making Custom Bushings for a Komatsu Wheel Loader - Heavy Equipment Repair Parts
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- เผยแพร่เมื่อ 1 มี.ค. 2024
- One of my customers is in mining, and uses some very large equipment. Their Komatsu Wheel Loader was getting loose in the bucket pins. They wound up line boring it and had me make custom bushings.
Komatsu quoted them almost $400 each for standard bushings and would not entertain custom sizes. I made these out of 4140 prehard for way less, and exactly to their specs.
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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Proper production in operation, many don't realise how planning of OPs is a big part of manufacturing.
Great job Josh, and thanks for sharing.
Without a plan, the job can go sideways real fast. Also planning for it to go badly is a great help. What can go wrong, and how will I overcome it.
That deflector is a freakin’ neat idea. Simple - effective - Brilliant.
I was thinking of adding that on even before he even thought of cutting.😮 what do I know I have a 7 x 10 central machinery, mini lathe😅. 80 T gear (plastic) broke😅
I used to use rubber discs cut from sheet with different size bores, that way you can stretch it over the shaft and it spins with it and flings everything off.
Early on I had the feeling that a chip was going to end up creating problems with the steady rollers. Been there before
Another fellow i watch would usually place a series of duct tape on his steady rest. I did enjoy the trick with the cardboard.
@gottagift No chance I would ever do anything like that. That glue on the tape sticks to everything, making a bigger mess in the end. Also it attracts more dirt and grit, a good machinist would never do anything that jeopardizes his equipment.
Showing off that new lift
The sound of the chips hitting the cardboard is pretty satisfying
Mr. T. I live in the Eau Claire area and love your channel.
Nicely done Josh ❤❤. Take care of yourself and family and friends and be Blessed ❤️.
I like that slick height change of the chamfering tool.
Happy days Josh, nice to see some real production shop work buddy, glad you have the job and thanks for taking us along.
Liked the intro btw, bet that took more to make than you would think
It wasn't too bad, but still took a bit.
Just before you added the chip shield I said to myself "Self - I wonder how long before he gets a chip under a roller?" It only takes once to discover it sucks.
Kurtis is going to be bummed out he didn't think of that cardboard trick. He usually uses the old painter's tape trick.
That glue on the tape sticks to everything, making a bigger mess in the end. There is no way I would ever do anything like that. It is just a bad idea all around.
Same here. Was thinking about just before the thunk.
Josh love your vids but i want to say one thing. I worked for years in a very large machine shop in nothern new york. No one was ever alowed to load a machine with a magnet for any reason. Bad things can happen . keep up the great work.
I agree. I used it this one time, I generally strap everything. I only got the magnet for plate lifting, it just happened to be easy for this.
Yup it’s coffee with topper machine Saturday morning tomorrow it’s snowball eng
Sounds great!
I hope your customers understand the amount of time and material costs involved in a job. Great work.
They absolutely do. I'm very open about the costs of everything and keep them well informed.
I really like the way you do machine work. Very precise and very efficient. It is nice to watch someone that really knows what they are doing. Very cool.
Thank you very much!
Yep--plan your work and work your plan; until someone else's emergency becomes yours. That's life alright. Nice work, Josh. Thanks and see you in the next one.
Josh,
Is hard to express how much I loveeeeee that LION lathe of yours, the more I see it the more I'm impressed. Excellent excellent job...both product production as well as the details in the camera work. Long and stringy chips to nice a blue lil ones...up close and superb details....got a lil concerned in the parting when I heard the squeal and start of the chatter, but you remedied the situation and explained to those NOT knowing....why you did what you did.
Temps here have been up and down +40F one day and like last night down to -5F with a bitter wind making it colder than a mother-in laws kiss.....tonight is already only +2F with tomorrows forecast for +35F....thank goodness the snow is melting faster than it has accumulated....maple syrup producers are screaming bloody murder its hurting them, but hey, our prayers to your snowblower.seem to have paid off...LOL....
Early day in the shop for me tomorrow, abt 1/2 way thru doing a precision gun part....a trigger..ughhhh only 3 /10ths total allowed tolerance then off to my surface grinder and skim off 1/10th then change wheels on the grinder to diamond and polish off another 1/10th.....then 6000 grit diamond paste and lap to mirror finish.....will take all day, as you know 99% set up and measuring and rechecking, and 1% execution
Keep up the great work...
Don
Thanks Don, it was a fun job. Today was bitter cold, even in the 30s. 6° when I woke up. Monday is supposed to be nice, so Conner is starting on the next phase of the crane rebuild. I don't miss the days of gun parts much. That's where I started, a punch press shop doing gun parts. It was fun, but I prefer big parts now days.
I like seeing him doing this and learning from you....we need more of others doing the same before the manual skills are lost and all they can do is use their thumbs and fingers to punch keys....I agree w Stuart abt the deflector.....sounded like a drum w the chips hitting it....@@TopperMachineLLC
I love the deflector it enhances the sounds of the chips.❤
Its crazy how hard those little cutting bits are!
Another interesting heavy machining video. I was just getting ready to warn you about those uncovered rollers when click it happened. That Vevor magnet is a very useful tool.
That cardboard shield is brilliant!
Thanks, Josh. Beautiful work.
Great video thanks for sharing
Nice job Josh. I always enjoy your videos. Thanks for sharing.
Strange as it sounds, sometimes increasing the speed when you get chatter / squeal on parting helps if using insert tooling! Tip I saw on another channel.
Clough42, probably. Speed up and press harder when parting off,IIRC
Thank you Josh!
Excellent as always. I absolutely adore that Lion lathe. I love to watch it and listen to it. It's exactly what I would want in a lathe. Thanks for another enjoyable video.
Thanks. I love my Lion lathe. I looked at a lot of machines before settling on Lion and couldn't be happier with it.
I always have been interested in machine work, looks great.
Nice work Josh.
That DOM Material has a nice finish.
The bushings look great. 👍👍
Can't ask for any better than what you did here.
Thanks for sharing.
Great job done right the first time. Thanks for the video keep on keeping on.
Super finish on those bushes Josh. Enjoyed the video. Cheers Tony
Great video as always
❤ ur lion.😂 Josh you should make a calendar for the 12 sexiest parts of the year😂😂
Lol.
Nice work as always, Josh.
My cat went crazy from the resonance while you parted off that first part. Funny as h3ll to watch.
I tried so hard to cut the sound there. I still wanted it in the video, but you should have been here. Ear plugs did not help. lol
The brake disc/drum lathes have a rubber band to kill the resonance. "Brake lathe silencer band"
@@erik_dk842 A trick I used to use was an inner tube for a garden tractor. Put inside and inflate. It worked great until I needed it for my garden tractor. LOL
I have just tied strips from old inner tubes around the outside. We've got a couple dozen train wheels to do and the flange forming tool will chatter and ring like crazy if we don't dampen the ring.
@@beyondmiddleagedman7240 It is my understanding that the noise in itself isn't the problem, it's that the surface will get imprinted with with a waveform, just like an old vinyl record. That's why the brake lathes come with silencer bands
hello Josh & it's is Randy and i like yours video is cool & Thanks Josh Friends Randy
great job thanks for the content
wonderful Josh, best wishes from Florida, Paul
Good stuff
This was a cool project. Great idea to use the cardboard
excellent vid thanks
good job 👍
Great video, like always Josh! 👍👍
Glad you enjoyed!
smart idea with the cardborad
if those are to support
Relative motion proper term is a bearing good work
Nice work Josh well executed!
One suggestion though I learned the hard way. Always make sure to clear any and all chips out of the way before each last finish pass!
Doesn't matter as much when roughing, but you don't want to take the chance of a chip buildup grab on your finish pass.
Good stuff, glad to see opportunities turn into profitable work
Me too. Not a lot of opportunities in my region.
Hope you got the rush job done in time to enjoy your evening plans.
I look forward to all your videos 🎉
Yup it’s becoming a ritual CEE , snowball Eng , IC weld and top it off with topper lots of laughts
❤️ C.E.E. Fri mornin🤩w/coffee in hand.
Before I even start to watch, a good job for Conner, is to make a air of knobs for the hydraulic levers on the forklift. 😉😊
He has plenty of real jobs to do. Vanity jobs don't even rank on the top 100.
NICE
hi there nice work , best to all john
Great style of intro
Glad you like it
While parting, it was nice to hear the tone going down when the cut was getting dieper :)
That is such a a cool sound on hollow parts.
Hey josh the lion is doing good
Life is easy when you have a lathe that cuts straight ! I used to make quite a few of those , same material in the days before ID welding was common for the line borer . Would always put a small lead on one end so they could start the bush square . Did they go slightly oval after parting off , that used to happen alot ! Cheers 👍
This material is quite stable. It held round. I think if it were thinner wall of may have had issues
25 kids cutting cardboard with ball peen hammers, the kindergarten teacher’s nightmare! Love it.
Yup years ago we made flange gaskets the same way
i usally work with reparing and maintenance of container lifting yokes, however i do get the "odd jobs" now and then doing repairs on forklifts etc.
my recent odd job was to lineboar a forklift with a claw that takes the logs of trucks, and i tries to suggest to them that a bushing would be best to put there seanse it would be easier to replace when it gets worn. however some pencilpusher decided that they wanted it welded and bored so the tap would fit. done many bushings for machines usally made from FE510 seanse it durable, but always nice to see someone else do them
Josh that Lion Lathe is the best. Nice Machine I live in California but travel a lot. If I ever get up that way I would love to stop in
Absolutely, just call ahead. I am out quite often.
Nothing like a coolant steam bath. I can’t tell you all over the many years of working for Martin, sprocket and gear running those Warner and Swayze, 3AC and 4AC turret lathes I have had my share of steam coolant baths.
I never thought of or seen a bolt used to catch a "part off".
Nothing better than chips being made at Hyperlapse speed while a piece of the original audio is played at normal speed.
I think your seeing real speed audio and video. I push that hard. Time is money.
I see you're up north of where my family and I used to live, back in '72/'73. We were living in Prescott at that time, having moved over from Maple Lake. I wasn't there long, going into the Navy in '73.
I literally was going to comment about those chips going in the rollers at 8:40.
Intentional to show how it happens and what to do about it.
Josh I would guess the original was made from a forging. Just because of the material you have to remove. Awesome work
This is DOM Tubing. I ordered the closest size I could get to finished. There just wasn't anything that close.
I am surprised that dom tubing has that much run out. Even the big stuff is usually pretty uniform. When I worked for the Boeing company I ran a Warner and Swasey #5 turret lathe making all manner of bushings. It is amazing how accurate the old monster was. Then for our smaller high tolerance bushings we ran Hardinge tool room machines. Over the 13 years I probably made thousands of bushings both straight and flanged type. Making bushings is one of the most boring things you can make but I didn't mind. It all payed the same...
The last 5 or so years, I've seen the DOM get quite bad. It used to be almost perfect, now it's all over the place.
Stefan Gotteswinter also released a video about bushings today, only his were teeny tiny made out of carbide :D
I have great respect for the guys doing the tiny work on manual machines. I want nothing to do with tiny parts. Big parts are a lot more fun. It's always interesting to see how much something big grows or shrinks as you machine it.
I wonder if you could shorten up your cutoff blade to help with the squeal. Those Aloris holders with the built in rake are a pain to adjust however. Whenever you move the blade you have to change the height as well. I switched to Iscar SGTBU tool holders a while back. They're just a tool block with neutral rake so you can move or change out the blades without adjusting tool height.
I should have shortened it, but then it would block your view also. It is a compromise to do these videos.
I really wanted to see you make the other 6 bushings, so I watched this video three more times. But what I don't understand is, why you waited each time until a chip landed in the steady rest rollers before making another chip shield. Did you not learn from the first time???
:)
just before you made the deflector i was thinking to myself why isnt he worried about the chips getting into the steady rest rollers.... not sure if i just hung out around there if i would just slow you down or speed you up lol pretty sure the later of the two
Thanks for the video Josh.
just a small point I noticed that you do what most YT people do when internal chamfering you raise the tool up to give clearance , as you have your tool holder double ended why not pack up the tool that you use for internal work but leave the other one as is . then you would not need to adjust on the fly
Just raising it a bit is far faster than pulling it off and turning it. I have 2 tools on there for different types of work. The way I used it in the video was for end work, and the other way is for when using a live center.
@@TopperMachineLLC ok thanks for the update
If the tool is on center and there’s plenty of clearance I don’t see any need to raise it. Must be missing something here?
Most of the time there isn't enough clearance for the chamfering tool. Raising it works best. Actually, I get a better finish doing it on larger stuff as well.
If you were going to go to the trouble of removing the tool holder and spinning it around to use another tool mounted higher, you may as well change the holder for one with an internal chamfer tool fitted. Just lifting the tool holder in the toolpost is the really efficient way to do an internal chamfer if the toolpost allows for it.
When you were chamfering the bushings, you kept raising and lowering the chamfering tool depending on whether it was cutting inside or outside..... was that to reduce chatter?
Inside tool height is slightly above center line, outside is just below. I exaggerate inside because the bottom of the chamfering tool can rub before the carbide makes contact. It's something I discovered a long time ago and the old timers I worked with were floored that they never figured that out. Lol
A question from the uninformed. Did you make a note of the DRO readout for each time you hit the measurement? So it was quicker for the next piece. Feel free to laugh at my question if it’s stupid!! Great work as ever.
It's not a stupid question. Yes, that is how I do it. Most DROs have tool programming to set offsets, I don't use it on the Newall because I've had so many problems with it that I don't trust it.
Hey, another great one! How do you heat your shop?
In floor radiant with electric boiler and heat pump.
At last!
The cardboard is a great idea. Why didn't you hog off the majority of the OD for the entire length at the beginning?
I didn't want to thin it that much right away because of the harmonics. It would have howled way more than it did during the parting. This stuff was hardened and that generates a high pitch that only gets worse. Leaving more material reduces that.
@@TopperMachineLLC Yes, mass is your friend when there’s a danger of harmonics.
Nice job. But you could have done with about half the stick out on the parting blade.
Is that an Iscar Tang Grip? I have the same one, lovely parting tool.
I left it from the last job, I didn't want to take the extra time to adjust stickout. It had been corrected on the following parts.
11:31...the chips hitting the cardboard sounds like a couple
of crabsfighting one another......
What a BORING video. Sorry, I had to say it.
Great work Josh! I really liked the little trick of raising the cutter for the inside chamfer, then a quick flip of the wrist to drop it for the outside. Little time saving details like that show experience. I've never thought about doing that.
It's something I came up with years ago. Even the old timers I worked with were shocked that they never thought about doing it.
put a big rubberband around it.
Very nice. I believe Komat'su equipment is made in Japan and would be a metric machine. Did you convert the measurements from metric to imperial, and do you find that is the best way to machine metric parts? Thanks. Regards.
Generally, I convert. But in this case, the customer gave me the measurements to use. They line bored everything, then gave me specs. Factory specs on the pin to bushing fit was something like 0.035 Slop, I tightened it up to 0.010. They are super happy with the fit.
Nice job. Did I end up in your spam folder too? 😂
I got it, just haven't had much time to respond. Sorry. It's been a crazy month here.
Check your spam. I replied to your email right away and again this morning.
Very nice
I think i missed it
What was the purpose of the cardboard?
Deflect the chips from the steadyrest rollers. If you go back, you can hear one go through. It was awful.
@@TopperMachineLLC Kurtis at CEE Australia uses strips of heavy duct tape to shield the rollers. Works well and more waterproof than cardboard.
Tape leaves its sticky goo on everything. I hate that crap. Tape also costs money, whereas cardboard does not. I have piles of cardboard laying around, if it gets wet and falls apart, I make another one.
I'm surprised that you could find DOM in 4140. It's generally supplied as HFS, or HRS, depending on your nomenclature. It's a hot rolled tube, not a DOM tube. As irregular as your dimensions are(your smoothing cuts), I'd guess it is a hot rolled tube.
Because it's pierced by a lance during the rolling process does not make it drawn over mandrel. Drawing is a cold process generally limited to smaller diameter tube. You might want to check with your supplier. HRS is generally cheaper because the dimensions/tolerances are looser. It's a tradeoff. A supplier should not knowingly sell hot roll as cold drawn.
The spiral pattern in the bore, which shows in your video, would indicate it's rolled tube.
Great work BTW. I always like your work, even though I sometimes give you grief about some of your safety gear while cutting with an O/A torch. Please use the proper shaded eyewear.
I went back and looked, and you are correct, it is not DOM. But I can confirm the last several years the DOM has not been great. Huge difference from my old stock(5 years old) to current stuff.
Would it be easier for you when boring to leave a witness mark by going in a little deeper
Just curious
No, I just use the DRO to know just where I am.
A machinist somewhere in B81 is wondering what happened to that dam tool holder.
He's not getting it back. Lol
Why not run coolant while cutting instead of in between cuts? I'm assuming to keep it from flying everywhere, but I want to know if it's for a different reason.
Mess, 100% about containing the mess. I shower once a day, I don't want to do it multiple times. LOL
I like watching machining videos for some strange reason. I know nothing other than watching.
Why did you not turn down the entire finished or close to OD, in the first setup? Then install the steady rest.
Like I said, "I know nothing," just curious.
It was for stability of the material and harmonics. You heard how bad it was when I cut it off, it would have been worse if I'd have turned down the whole length.
Two comments I find it strange they didn't require a T- bushing, and what is your reason for not running your coolant constant, very interesting video beautiful work.
It was line bored to what they wanted. As far as coolant, I like to take 1 shower a day with water not coolant.
@@TopperMachineLLC Not to mention a coolant flood out through the end of the work tube when boring.
Just curious as I’m not a machinist but I do enjoy your content. I realize it’s partly do to filming for visibility. Why sometimes run coolant while turning and sometimes no coolant while turning??
Coolant isn't always necessary. Mostly, I don't run coolant on higher speeds because I don't want to take a shower in it, I prefer warm water. There is nothing wrong with dry machining, you just need to watch temps and know your tools.
Do you know the Strunks?
Bro, you're a machinist - make some proper knobs for the controls on that forklift.
LOL
Why waste time on unimportant things when there are paying jobs to do?
@@TopperMachineLLC Oh I know man - just messing with you.
It's one of those things that gets under my skin in my shop - and is always in the back of my mind - but yes, it gets pushed to the bottom of the list as long as there are more important things that need to get done.
Just curious, if you do not mind, how much did the 6x1 4140 cost.....
I could probably look up, but I am interested in current material price.
thank you in advance, Paul
This was almost 2 months ago now, I am quite behind on the videos. I would have to look it up to be exact, but I seem to recall around $430.00 delivered. I didn't think that was too bad for that chunk.
He’s using part of cad now,the cardboard part.
What’s the purpose of dropping the chamfering tool instead of keeping it in position for both the ID & OD
Tool clearance mostly, but also finish. For od, the tool is just slightly low, not much. On the ID you want to be a touch higher than center. I exaggerate it for clearance of the tool. Otherwise the curve will hit the bottom of the cutter.
Many thanks!.. I’ll try that next time
I wonder how many of us watching said, NEEDS A CHIP DEFLECTOR, like 10 seconds before?
It was all for show, now everyone knows what can happen.
GOOD JOB!@@TopperMachineLLC
I hope you see this comment..... I've told a lot of people about trying to use the parting tool upside down, lathe in reverse and you'll have almost NO chatter. there's a good video explaining why this works if you want to have a look (every time I put a link to another video anymore my comment gets automatically deleted, this is the second time I've made this post, I'm leaving out the link so hopefully the you tube overloards will leave it alone. the title of the video I want to link is "The Ultimate Trick: Cutting off with the Mini Lathe ") He actually goes into why it works so well
Thanks for the info. I will definitely look up the video and watch it. Up until I bought the Lion, I never had a lathe with reverse. Monarch's are one direction, and for good reason. Reversing a Monarch is not good for their internal drives.
@@TopperMachineLLC Yea I don't know why you tube won't allow links in comments anymore (maybe spam concerns) but I've noticed it in the last couple months :( I'll make another reply with just the link and see what happens
Why did you change the height of your chamfer tool?
Inside tool height is slightly above center line, outside is just below. I exaggerate inside because the bottom of the chamfering tool can rub before the carbide makes contact. It's something I discovered a long time ago and the old timers I worked with were floored that they never figured that out. Lol
Should show that cardboard tip to Kurtis, better than tape.
You'll know if he watches, if he starts using my copyrighted idea. Looking forward to my royalties on this one.
@@TopperMachineLLC
Tongue firmly in cheek , I have heard of CAM ( cardboard assisted manufacturing) but that takes the biscuit 😎
4:40, man I hate those types chips, only thing worse is the very long
almost straight chips that come right at you and want to grab you
like a vine in a Tarzan Movie.......
as we say down here in the South 'any ID ? '....about what ???
So why not run the coolant all the time, like other machinists do?
Mess
Arme man, het is 2024 en hij werkt nog steeds met inches!
I feel bad for you, working in metric.
@@TopperMachineLLC succes met je inch-foot-yard-mile-acre-gallon-quart-pint-teaspoon-tablespoon-ounc-pound.......HILARISCH! 🤣😂😁