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Thanks for the education on spray welding. I was always curious on how that works. Fucking Homie…….🤣😂 he wants the whole bag of treats. Homie is awesome
With that professional job, if i were the contractor, i would just put that new part on the shelf, and not bother swapping out this "defective" one. What a masterful piece of work, it will probably last the lifetime of the machine to be honest. Unless someone else does something dumb, like dropping it :)
@@JohnDoe-bd5sz I was thinking exactly the same way, mate! If CEE's patch is holding, why waste time, money and effort to change out the part to no practical benefit? If it was cracking and leaking, fine, have at it, but if it was now covered in dry mud and difficult to find, why bother? Kurtis is way, way good enough.
Being a welder fabricator for the last 39 years, I've got to tell you that was one of the most impressive repairs I've seen. May even be your best video so far. You are pretty damn sharp. Thanks for showing me something I didn't know.
Genius! I did my city guilds back in the 70's and we used to take it in and out of a forge to stop it cracking, but that is waaaay the best I've ever seen ! Thumb's up! Mike in England
*Brilliant repair. We rarely use our hydraulic press as a sheet metal brake for the big stuff but you made that thing look like a ring roller lol. In Alaska a machine being out for a day might be a $20k loss but even parts that are helicoptered in from the closest FedEx station might take ten days to get here. As for the appearance, I've never met a lady yet who cared what the transmission housing on a Ferrari looked like.*
Lift operator; Hey, It was Not my Fault, it was that "Gravity" guy. lmao Did not know you could even try to repair Cast Iron with any torch. Never even heard of "Flame Spray Welding." Guess I need to get out more.
Yes quite a nice explanation, reminds me of my first nasty boating experience (broken propellor blades) the mechanic explained to me… “oh yes we get a lot of these type breakages all due to hard water”
@@michaelwellman2079 I know right? I have always brazed to do the repairs on cast but day-am that looked beautiful when he was done. Now I want a puddling torch.
40+ years as a welder/fabricator/repairman…I’m ashamed to admit that I’ve NEVER seen this process. You can bet that I’ll be researching like mad! Love your channel mate! Cheers!
Flame metal spray has been used for decades to repair worn shafts or apply hard metal coatings. The trick is to preheat the parent metal. It’s risky as you can damage the underlying hardness.
Flame spray for shaft repairs has been around at least 50 years. I’ve never seen it used for welding. But the (relatively) diffuse heat makes good sense with cast iron.
I've been welding 59 years and have heard of flame spray welding, but have never had the opportunity to see it done. Thank you so much for the concise explanation of the prep work and of course seeing the flame spray welding. Enjoy watching you work. Thank you from Dallas Texas
I have to say, Curtis, from my perspective, you’re a young guy. But your skill and knowledge equals that of people in the business for much longer. I really enjoy watching these. And I thank your wife for doing such a great job with the shooting and editing of these videos.
I'm not a welder or fabricator, but i have been around a lot of it in my career. This is the first time I've ever come across powder welding...fascinating!
Same here! Never heard of a puddle gun in my 43 years. It's probably one of those tools, not the kind of thing you need every day, but worth it's weight in gold when you do. I can say, I've had to do quite a few cast iron welds in my time, fixing machinery mostly, and one of those guns would have saved a lot of swearing over the years.
I know you don't like being on camera but you definitely have a gift for explaining things so the average person understands it. I've never seen any sort of heavy equipment up close but you make it easy to understand what each part does. You truly have a gift.
This dude is spray welding powder through a torch! How does he have the knowledge, experience, and established business of a seventy-year-old man at whatever age he happens to be? Curtis from cutting-edge engineering never ceases to amaze me!
@@CuttingEdgeEngineering I was introduced to spray welding in my first year as an apprentice, did quite a lot of different repairs with a eutectic Castolin torch, building up shafts, cast iron repairs and hard facing etc.
As with all of us our trade gets better as we get older right up to the point where we forget how to do everything except tell the stories that go along with it. Hopefully young ears will sit and listen to our stories and collect some of the knowledge that we've learned over the years...
“That will do!” Are you kidding, that was pure brilliance! 👌 Each week I am in total awe at what you are capable of doing, and the fact that you and Karen take so much effort to share this with the TH-cam community. 👏👏👍😀
I totally agree, and Karen ain’t no fool- she probably makes a decent bit of cash by filming all this stuff for us appreciative viewers. 👌 I really love these vids, nothing is impossible if you believe you can !🏴
I used to use this method of repair on cast iron many years ago while in the automotive trade. I’m glad to see that in the right hands it still has its place in our modern world. I’m so happy to see this almost forgotten skill still being performed by a truly talented tradesman. You’ve made an old man very happy. Thank you.
Having performed many cast iron repairs over the years all I can say is "Wow that puddle gun technique is impressive" and exactly what the Dr ordered for this repair. Great job fitting the plate and the follow thru, you are one mighty talented young-un! Want to bet that the owner / operator will just smile, pay your bill, reinstall the part and run the machine without ever replacing the housing? After collecting the insurance $ that is LOL! BTW as talented as you are you probably consider yourself "the talent" of this channel but I hate to tell ya that the dog and the wife are stealing your thunder! Oh well, "this is the way".
Hey mate, the missus and Homey agree with you 🤣 thanks for watching glad you enjoyed this, i'm thinking the new part would just go on the shelf as a spare 🤣👍
i would still put the new housing. with the steel to cast iron you are asking for trouble long term. if it cracks later from vibration and you lose the transmission fluid is the insurance going to buy you a new transmission. i kind of doubt it.
@@CuttingEdgeEngineering Yes, never seen that use before. Have done the bronze plate though, to fix up bores that were somewhat less than good, to get them to the point the shafting that ran in them, or at least the new shoulder bolts I used, would be a tight fit. Holes wallowed out, and the original pins were under 5mm diameter at the wear points. No way to get spare parts, seeing as the manufacturer, still in business, no longer supports a machine they made in the 1970's, and have less than a clue, though the parts likely are still on some of the modern versions, seeing as they likely use a similar version of the linkage. But the braze and drill was both faster and cheaper, and the shoulder bolt was $3, off the shelf. Now to get some flexible pneumatic cylinder shaft couplers for it.
Great repair. Wished I had known of this method 40 years ago when I repaired my 1948 Willys L-134 block from a freeze crack. Cast is such a pain to fix. Seeing that grader hit the ground would have been a reason to kill or cry on the spot. Great repair job. Nice work as always Karen, and Homeless is still trying to steal the show.
@@CuttingEdgeEngineering really hum 🤔so a 1970 BBM/iron hemi needs a new/taller 4140 deck/cam/reinforcements/modifying ( making a costume 1-off isn't in the cards for now plus im experimenting/R&D/working with a cheap boat anker aka polish a 💩to gold ) and id like the raze/fix the D-8 cast iron exhaust ports some and i have a investment cast SS shifter part out of a 2014 tr6060 transmission that needs some small tweaks/mods to work with my application and jb-weld isn't enough/cutting it even as a mockup/test fitment on my transmission bench. so this gas method vs TIG vs stick which is the strongest/perment repair? and im sure pre slowly upto 1500F and after heating slow cooling is needed for both repairs? but i haven't done big cast parts like a block before or cast SS parts but have done small tractor iron junkyard scrap's as practice when i was first learning how to weld 20 ish years ago and for usa 🇺🇸 localities a local welding supply can get the consumables? or call the place in Texas only for spay welding equipment? as i mostly do tig but have done other AWS welding methods like mig or gas rod it just isn't my favourite
@@cliveramsbotty6077 hah vary funny 😆you have to be trolling for the lol's 😂, that or you didn't see the flag 🇺🇸 or read the hole comment/real question i have
@@CuttingEdgeEngineering to add to the question does this gas spary work better for cast aluminium parts as well vs tig as some cast car parts like older transmission housing's and intake AL manifolds are really dirty/have a lot of junk in them are are hard to weld. and that one i did find out and on one of my per-1990's part's tig worked but look's like crap but my al welding doesn't happen to be the best but it's ok vs my SS steel welding technique's. and is there a replacement method that uses electricity instead of occ's / O2 & asenalene or natural gas?
I'm a certified welder and retired.. I used to do spray transfer welding on heavy parts for United Steel here in the US.. I'm very happy with the videos you are doing.. Keep up the great work you do.. The big boss Homeless should give you and the Mrs. A raise.. have a great weekend..
Welding cast iron, such a nasty job that never turns out good in my limited experience. Was very nice to see you do it, really opened my eyes on what someone who knows a thing or two can do.
Don't bother welding cast iron. Only lucky, or experienced people can pull it off, even when perfect tools are involved, and since this method ain't for everyone, learn to braze. Braze and cast iron go together like beer and pretzels. In this instance, for example, brazing a T profile plug, would make the whole area stronger than original (also, same principles apply, you can put a dissimilar metal there, as long as braze can stick to it). Back in the day, when brazing was part of the bread and butter, they used to braze steel strips over cast iron housings (think banding on a barrel) to make them stronger. I've seen housings from old, old Cats break crushers with this mod at the junk yard.
@@aserta Yeah, I probably would have gone with brazing in this situation. Much less chance of things going wrong and having cracks form later. Still Cutting Edge does good work so I doubt this thing will fail anytime soon.
Recently found your channel and subscribed. As an automotive fabricator for nearly 30 years I can appreciate the knowledge and skill you have. You are also a natural when it comes to explaining repair procedures and the video format works great, well done Mrs Camera person/Producer/Editor. P.S I live in Staffordshire, home of the Staffy :)
This is freaking awesome. Never heard of this type of welding. Love that you don’t limit yourself and are willing to do what it takes to help the customer. Great customer service is so hard to find anymore. As always, great videography from the boss.
Regardless of what it may be, I will never tire of watching a true artisan apply their trade. With CEE you get it with both barrels, the engineering is first class and the video work is right up there as well.
What an absolute Pro !! He ran up, found the problem and then Curtis jumped in to fix it. Great camera work as well. What a fantastic team. Keep up the phenomenal content !
That's a pretty cool way of doing it. I've had 966 loaders that guys have busted the housing on just like this and always used 99 nickel rod. Takes forever that way but it works, I'm gonna look more into this. You have imo the best machining channel on you tube btw!
Ola amigo tudo bem. Eu nunca tinha visto esse tipo the solda eu gostei ds forma que ele soldou. Gostava de ver a forma que voce solda esse tipo de fetto fundido. Um forte abrscao de Londres Inglaterra 🇬🇧
@@CuttingEdgeEngineering that welding technic is used every day in the factory I work here in Portugal. It is used to repair cast iron molds, it is a glass factory... Love your videos....
I am totally addicted to this channel, which I have been enjoying for a year or so. My late father was a machinist and toolmaker; our shed at home was full of tools that I got to use during my teenage years. Sadly, I never got to run a lathe, but watching Curtis comes very close!
Worked for a Cat dealer in late 90's before removing the engine on these motorgraders the shop foreman insisted on personally checking that all the trans/engine flange bolts were removed. Evidently some mechanics in the past were not very careful in removing ALL the bolts and broke an ear off more than once, to which the dealer had to end up paying for a new housing. Your workmanship is second to none!
I freaking love problem solving! I excel with problem solving when it comes to carpentry and rehabbing! It's the best feeling knowing you thought up a way to fix a big problem. Awesome job!
The customer is lucky to have you available to attempt such repairs. I'm sure it'll hold up and will definitely offset the cost of the parent machine down time. It doesn't look sh1t at all, for a cast repair, it looks amazing.
I've never heard, let alone seen, powder welding and it is a Fascinating process, along with your explanation as for the reason of it's use on this occasion AND the way your "cameragiggle" records it working, was brilliant. Always a joy to watch the videos and repairs by someone with numerous skills and able to explain the whole thing in a simple way. Wait to see and hear the "outtakes" at the end, always a joy
You always seem to have a really interesting problem to solve. A lot of thought even before the lot of prep. Awesome skills! And Karen does a super great job of video and editing - big thanks to her too. All brilliantly supervised by Mr. HBB himself, or course.
Thank you for taking the time to explain how the "Puddle Gun" (is this the spelling?) works. Never heard of it before. A very clever principle, like a paint gun that paints with molten metal. Always see other people on TH-cam getting stuck when it comes to welding cast iron, but for CEE, it was just another day and another job well done. Kudos!
Great video. I've been welding for around 50 years off and on. This is the first time I have seen the puddle gun technique being used. That's quite impressive . I worked for a company that used a flame aluminumizing technique, but that was being used as a protective finish and not a structural repair. I would like to see more of this technique being used. Again , great video.
I just knew that I was going to start seeing cracking everywhere and was amazed when I didn't. That was the best cast iron repair I've seen to date. that's why I tell everyone to watch your videos if there wondering how to fix something right. great job and great Video thanks for sharing
In the early 1980's I worked for STRATA welding. I used to sell a hell of a lot of spray powder gun kits and spray powder, mostly for cast iron repais. I notice that HARRIS also have a great kit. Good to see you still using this type of equipment.
That didn’t even look like it was a challenge for you. You made it look like a very straight forward, common repair. Beauty is in the eye of the beholder. To the customer, that repair job looks like $$$.
I'm a machinist for a Cat dealer in the USA and spray welding is extremely common as part of out process. We spray weld nearly everything that needs material built back up. Even bearing areas and seal bores will get sprayed and machined back to size.
@@stevo450ify being able to do it ourselves is basically a necessity based on how much we do it. Yokes, pistons, brake anchors, duo cones, housings and hubs are the components I specialize in and everyone of them gets sprayed in one way or another to be able to recondition them.
Well done !! I first used spray welding in the early 1980s, in the USA. You did an excellent job. I would only suggest 1 thing. In each of the corners I would recommend using a ¾ inch carbide burr for a radius. The same way drilling a hole at the end of a crack relieves stress, so does a radius. The metallurgy of the cast-iron housing was of a high-quality with a high nickel content. Lots of elasticity. 👍👍👍👍👍👍👍👍👍👍👍👍
I'm a welder/fabricator with experience in this kind of repair. I can tell you this is one of the hardest repairs to perform, depending on the material. Grey cast iron is a nightmare, ductile is a little more forgiving, and mailable is almost as easy as steel. It depends on the carbon and silicone content, the distribution of the carbon and the grain structure. I usually use nickel/iron DC TIG or Alum Bronze AC TIG. But to weld steel in to cast iron is very hard, they have completely different coefficients of linear expansion. Steel, when heated, will always contract more than it expands. Cast iron hardly moves at all when heated, so the end result is, if it doesn't crack again while cooling, then stresses are set up that cannot be relieved by post heating, meaning that when the casting goes in to service there is a strong likelihood of it cracking due to operational stresses from vibration etc. The only way I have had any success is by peening the welds after every weld pass.
Hi Darren Garden, Just curious, I have a backhoe. Circa 1989. Back digger section held on by top and bottom pins. The bottom pin section holding the pin snapped through on both sides and made a very loud crack sound. Brocken area is like rough sand and a grey colour. Its some type of cast moulding. Its one massive section that the backhoe arm swings from. I did a spark test, sparks are relatively small and stay closer to grinder and are a red type of colour. It ships off like small bits of sand compared to mile steel where it peals off when using chisel. Any idea on how to fix this issue as its holding a massive amount of weight. The ram rod also snapped off when this happened. I had only just replaced the other ram rod which also snapped. Was thinking it is some type of cast iron? If so, would a Ni 55 or NiFe work? Also wanting to weld mild steel on outside to help support it. Was reading that Ni Fe can be cold welded. Any ideas greatly appreciated as this part can not be replaced.
Oh forgot to mention, I only have a gasless mig and stick welder and propane torches. Also, would be impossible to heat up the part as its still on the machine and weights a massive amount. Part that broke off is 50mm high and 40mm thick. Broke off in two areas.
@@marinetrax I used to make excavator lift arms and buckets. They are made from carbon steel and should be welded with er70s6 otherwise known as a18 mig wire or rods. Although mig is not recommended and dual shield flux core is recommended. Full penetration welds. Pre heat is essential or you will get weld embrittlement and it will crack. You also should post heat to stress relive, but not essential.
@@darren-garden Thanks so much for your reply. Muchly appreciate it. Just to confirm, this is the section of the backhoe that the digger attaches to at back of machine. It has the breaks for the side shift and that holds the top and bottom pin. It is some kind of cast. I looked up to see what type of spark carbon steel produces and it says yellow. The sparks off this is more red and small. Not as small as cast iron, but the same colour as cast iron. And its brittle, peals off in sand like pieces and looks "sandy" grey. Do you still think that this is carbon steel? I was looking at using Ni 55 or NiFe welding rods and doing it cold weld as its impossible to heat up the whole piece as its a massive cast section. Thanks so much. I would post pictures for you but I cant on here. Thanks once again. Also, I don't have gas. I only have a gasless MiG or stick welder.
That was an awesome repair you did on that housing. I’ve never seen it used for such a large fill. Well done Kurtis you are a very talented man, and the videography is second to none, great job Karen I love the videos. Peter😀👍🇦🇺
Brass has always been my go to for cast iron repair... This appears a bit less time consuming and less stress in the repaired joint due to brass pulling inward... Job well done...
Nice work Kurtis, I'm impressed. I own a Victor spray welding system and never knew they had a version for seam welding. Slickest cast iron repair I've ever seen. Sure beats the high dollar nickel rod that rarely works and only makes your scrap more expensive. Thanks for the demonstration!
Yes, got some of those rods, and about the best use for them is refacing mower blades, as the metal comes out really hard, so takes a lot longer to wear out cutting grass. Last lot though I bought new blades, there was not much left of the old ones.
@@SeanBZA great idea! I (think I) got a box of hard facing rods on some big sale and figured I'd never really have any use for them. But building up the mower blade, especially on the Bush Hog would be a good use for them. Thanks.
Kurtis. I made my living with a torch for many, many years and I loved it. There is a certain personal satisfaction of taking something that's broken and bringing it back to life and useful again. I'm retired now but still miss working with my torch from time to time. Bill from Linglestown, Pennsylvania, USA.
Definitely NOT your cut it close and let her rip everyday machine shop! SOO excited I found your channel. You are an ARTISAN in metals. You are so skilled with the work, set up of the lathe and know what to do to get results. I am so impressed and happy to see your videos pop up on my list. Some of the repairs you do well and beautifully make my head hurt looking at the initial damage but when you are done "VIOLA" it looks better than new! Your wife is a jewel (that you already know I am sure) and one heck of a videographer wow what some cool shots. As a photographer of 50+ years her cool use of filters BLOWS me away! WOW! As you can see over here in Mobile, AL in the good ole US of A I am absolutely lovin your videos, your wife's skills in shooting and editing the work. It's like going to class every time but way more fun than school I went to decades ago! Please keep the videos coming you have fans far away and near too I am sure!!!
Hey mate thanks for the great comment and support we both appreciate it a lot! Always glad to read when a viewer is enjoying the videos, we plan to keep making them for a while yet. Cheers
In all my 50 plus years of welding, I have never seen this method of brazing. Absolutely beautiful job on cast. It doesn't matter the looks as long as it works. Thank you for the enlightenment of a way of welding.
What a great video! TH-cam has shown some interesting techniques to repair cast iron. This one is clearly the best i've seen yet. I love the attention to detail you demonstrated fitting that plate in so well. Another vote that the owner will NOT install the OEM replacement case if this repair shows to a permanent fix after a couple of months of use. The repair looked exceptionally solid and if it didn't crack while cooling down, it should be permanent.
Not as if the part is going to be highly stressed during use. All it has to do is hold hydraulic fluid and provide somewhere for the pumps to fit. It's just a sump when all is done
This was all about the right welding technique which you were all over like a cheap suit as a result of your experience. You and Israel at IC Weld are both great problem solvers. Every time I watch your videos I learn something.
It's kind of funny I see weld and cutting edge they're 180° apart and I don't mean by the world their personalities but they both can figure out any hard part to fix it hey and they both have a dog we have homeless and we have wylie E.
It was very impressive watching you ‘persuade’ that hefty lump of plate to fit such an awkwardly-shaped hole. I thought at first that you would trim the hole to as near a rectangle as you could get, but no, you went the more difficult route! Nice job!
I just came upon this channel as I am always watching anything that has good-excellent "Maker" content. This channel by far is the most diverse in terms of both types of work that is being done and also the most heavy-duty work being carried out to mend any broken machine in that part of the world. Additionally, he is a very good communicator with detailed explanations of why and how about everything the does and is just a pleasure to watch and learn
Great Job! I know it´s kind of hard to get information on parts once they leave the shop but still I´d love to see a follow up on how the housing is holding up in every day use. cheers
@@CuttingEdgeEngineering I think so many people are looking at your content, and will be for many, many years, that updates on this and any other projects would be really great. You could even do a project updates video with a commentary perhaps? Reading through all the comments here makes it obvious how much you are giving and sharing to the global community. It makes me think of my Dad, who not long before he died lamented that so much knowledge and experience was going to be lost. You are certainly creating a legacy and making the world a better place for many, many people. Thanks for this.
On the same note.. would there be any gain in having a curve on the corners of the repair rather than a squarish corner... I know it is just a short term repair.. ????🤔🤨😀😁😎nice job.
@@rodmills4071 They’ll use this until the new piece gets delivered, & then continue with this one so that the machine can work, if it works don’t stop. There’s nothing more permanent than a temporary repair.
Yes, I agree a curved corner would probably be better. Over the years I’ve done many similar repairs and I’ve found from experience a hole drilled on the end of a crack definitely prevents the crack from extending. In my day we only had brazing or electrodes, this new powder technology is a big improvement.
I like these kind of videos. In the late 80s I heard about this process in school. Later in the early 2000s we had an axle housing repaired in this way. But I've never seen the process myself. Today I saw it for the first time, for which I thank you. I hope to see many more special repairs.
Brilliant repair, you never fail to amaze me with your range of skills and understanding of what is required to get a job done properly-no cutting corners. That repair will outlast the machine, the owner no doubt will keep the new part just in case ‘gravity’ strikes again. Fantastic all round team effort. Greetings from Tasmania Australia 👍😁🦘
Simply amazing work, Kurtis!! I'm sure the owner of that machine was elated to save 3 1/2 months of productivity! Even if you charged him triple, he got a BARGAIN!!
This is amazing. I'm a student welder / fabricator and have never seen this process before! Will have to ask my instructors about it! Looks really good, fast and effective!
I learned this process for engine casting repair for cylinder blocks and heads used a huge thermal cleaning oven for preheat of huge industrial blocks and heads there is good money in being able to do it
Great job! I knew of spray welding for shaft build up but never knew of this. Ive done the same type of work you do for most of my career. But you always come up with something I can learn from. Thanks for the video!
I used to use the castonil eutectic (spelling might be out but amazed I even remember that much, was a long time ago!) Powder to build up shafts. I guess it did what was required but it's actual strength in tension was terrible.
Hi, thanks for the demo on spray welding. As a teenager in the '60s growing up in Texas I had a summer job refurbishing oil well equipment(nasty work) only heard of a guy with a travel unit to do spray welding on worn down drilling shafts. Made good money back then. Your demo is the first time I have seen it done after all these years. Thank you.
It would be interesting to see how this repair lasted in the long term. With global supply chain issues, this could be in place for a year or more. Love the paint to finish the job. Always professional.
Man I love to see the old school spray welder come into action! It’s such a cool process to see. My dad was so good at this. He could repair any shaft that got out of round from a bad bearing or race etc and lathe it out to fix an obsolete part. Really cool to see it being done in this manner
This brought to mind a funny case from when I worked in a factory. We had state of the art Kemppi welders that could also weld aluminium. One lad thought he'd have a go. Put all the right settings and went to town. We had a good laugh while waiting to tell him that he forgot to change the stainless steel wire for something more suitable. I learned some new bad words.
Unbelievable workmenship!!! I love your one man band approach. It's amazing what you do. Your wife is an amazing cinematographer also! I can't wait for your videos. Even for a home machinist many of your techniques can help with hobby work! Thanks for the great videos!!
Brilliant repair! And by coincidence, I was cleaning out an old cabinet at work a few months ago and came across the Eutectic version of your UTP flame spray welder. Now I know what it is and what it can do.
With 35 years in the automotive repair industry, I have come to understand the difference between knowledge and Skill. Both have a genuine place in the repair industry but rarely seen in the same place at the same time. Hearing your opinion and how it was based on experience was refreshing. No bashing of other methods or skills, just preference based on experience. To watch your skill in completing the job was just as enjoyable. Having worked in the mining industry for a short period of my life I have a basic understanding of the reasoning behind your repair choice. I do have a question. I do not repair cast iron often as the kind of repair i am doing now rarely requires it. When required it is usually limited to thread repair. I am not a welder by trade so my question may seem dumb to you. Recently I was advised to use a bronze wire and a stainless wire twisted into one wire for filling a crack coming off a bolt hole before thread repair. it was a bit tough to get the mixture to flow into the termination hole for the crack. The rest of the filler material flowed correctly into the ground out area. I know it is tough to answer without seeing the issue first hand but your opinion as to what i could have done wrong would be welcome. In context I have never had a issue with straight bronze filler rod.
I remember years ago reading an article about "stitching" a cracked cast iron engine crankcase together after a catastrophic failure. The solution was to drill a series of holes on either side of the cracks then use "flat wire" to join them. Some brazing then took place to seal the join permanently, whilst the wire remained as a reinforcement. The article had several artistic photos of before and after. It seemed a legitimate solution at the time (possibly 1960's or so).
@@KW-ei3pi Yes, I was fascinated by that more modern version of what I read about. It seems to be a big business, but very tedious compared to what we saw on CEE's latest episode.
metal locking has been done for a long time. there is no welding or brazing with that method. i was at a shop that did that and they were fixing a locomotive engine block that put a rod through the side. they actually had an old block as a donor and using a 3/8 drill they " cut out" the section of donor block and broken block and stitched the part in. it was a 20k repair 22 years ago.
I've done this since I was 25, when I worked for Eutectic in Switzerland. But we made sure to preheat the whole part when repairing cast-iron parts, and slow cool in vermiculite. Kurtis, I think you were a bit lucky that it didn't cracked, but hey, the part was salvaged...
I think he didnt want the heat affecting the hydraulic ports so he gambled and localised the heat. Good repair and customer had nothing to lose just Curtis if repair failed
Brilliant repair and video guys!! Had only ever seen spray welding done on a shaft held in a lathe. Again, thanks for taking the time to go through what the tool is and WHY it is being used.
Hey mate! Glad we could show something a bit different for viewers, always good to know if people are seeing or learning something new. Have a good weekend mate
I've had cause to repair cast iron in the past (stick, brazing, stitching with threaded stock etc but all I can say after watching this is "wow"... I've learned something today. That puddle technique with that gun is nothing short of amazing. Your customer is very lucky. Thank you very much for posting that.
Really like the tight control with the spray. The others I have seen spray all over the place. Very effective use of CAD ( Cardboard Aided Design ). The repair looks solid, hopefully the customer is satisfied. On the lighter note, that tail of Homeless can be a lethal weapon once he gets it going.
CAD term you use joking suddenly got me thinking in this digital age... could be scanned then there's even 3D metal printers that fuse powder so you could get like 99% perfect fit, but it's obviously more time-consuming!
@@TheLazerhorse For ultimate CAD have a look at Bad Obsession Motorsport's Project Binky series, the ultimate expression of the art, oh and a few brackets lobbed in there too!
I admire how you didn't overdo the grinding. It needs to work for 3 months, its good for the repair to be visible through the paint, more grinding = less strength, just grind enough to make sure nothing gets loose inside the oil reservoir and to get good paint adhesion on the outside = perfect.
Dude, that was awesome. I’ve never actually seen that done before. It sucks you even had to do it though. I feel bad for the man whose grader was damaged in transport.
Fascinating demo of the spray puddle gun! I've seen spray welding but this is an interesting variant. Love to see more - that was a great repair and well worth it. Nice work creating the patch - smooth and efficient.
Freds Fabrications uk ,love your vids ,been self employed 3 year after kidney cancer ,35 year in industry and just picked up a Fortargen flame spraying kit very similar , i`ve had 90% success on 80 odd jobs but last 2 was a right mare , so will be trying this method , keep up the good work , i did 6 years in a place making loader shovels and telescopic handlers Matbro uk tetbury in the 90`s and was mainly stress relieving , lining all the bosses plate up after welding and overcoming the distortion , all the best fred just watched the vid again and the case and pots looks exactly the same ,megga
I work with aluminum, stainless and titanium and stay away from cast iron because I've never had good luck with it. Awesome skills you have, you made a very difficult repair look easy. Great video, please keep them coming. All the best from 🇨🇦
Same time where I’m at. I just got home from a long day at work, just in time to relax and watch this new video. Looks interesting. I’ve always been interested in this type of repair.
Brilliant job! Yeah, Alaska is about 2245 hours right now.. just finished digging through some frozen ground, but had to get in some CEE time before getting some sleep! LOL Back at it at 0500 hrs!
@@CuttingEdgeEngineeringYeah it’s pretty crazy isn’t it, that was an interesting repair, I hadn’t seen that particular type of welding before, I’ve seen the spray welding it not that, looking forward to the next one, thanks Kurtis
Kurtis, you remind me of my grandfather, he was a machinist, welder, black smith. I helped him in his shop. People would come from all over to get repairs done that on other shop could or would do. I enjoy watching you work, I miss him a lot, he passed 29 years ago.
Enjoying my morning coffee, watching my weekly Cutting Edge Engineering video and damn you every time they're more interesting! Never knew spray welding until I saw Abom79 doing shaft build ups, and now here you are using the same sort of method to actually weld something! Never to old to learn I guess! Great video as always. Take care guys👍🏻🍺
Fantastic job Kurtis, I’ve never seen a repair undertaken like that before. Why would the owner even bother replacing your repair job with a new housing?
I love how he takes so much pride in his work I work the same way. It drives me insane how I get rookies to train at work and they don’t take pride with the quality of work they do. Awesome to see someone else this way. Nice job man. Coming from USA 🇺🇸
It pleases me when I see that a part is being repaired with appropriate means and techniques. The craftsmanship is excellent. In Germany we say: The welder fills everything under an inch. Greetings from Germany!
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Why is the case painted on the inside? 😅
Thanks for the education on spray welding. I was always curious on how that works.
Fucking Homie…….🤣😂 he wants the whole bag of treats. Homie is awesome
With that professional job, if i were the contractor, i would just put that new part on the shelf, and not bother swapping out this "defective" one.
What a masterful piece of work, it will probably last the lifetime of the machine to be honest. Unless someone else does something dumb, like dropping it :)
Ha! I wrote a comment about spray welding some weeks back, thank you for this video!
@@JohnDoe-bd5sz I was thinking exactly the same way, mate! If CEE's patch is holding, why waste time, money and effort to change out the part to no practical benefit? If it was cracking and leaking, fine, have at it, but if it was now covered in dry mud and difficult to find, why bother? Kurtis is way, way good enough.
I've been a welder for 153 years. You did an amazing job
ive seen you in a few weird places saying weird things makes me think you where hacked
@@alfonsoalonzo Or maybe he got whacked in the head
@@anonymousarmadillo6589 that would be on brand but its almost like spam bot seriously strange
Bruh
Wow is your name Moses ?
Being a welder fabricator for the last 39 years, I've got to tell you that was one of the most impressive repairs I've seen. May even be your best video so far. You are pretty damn sharp. Thanks for showing me something I didn't know.
wow thanks mate appreciate you saying so!
Well said. Whole heartedly agree! I don't know that it's the best video because the bar from this channel is so darn high!
Genius!
I did my city guilds back in the 70's and we used to take it in and out of a forge to stop it cracking, but that is waaaay the best I've ever seen ! Thumb's up!
Mike in England
I am not a welder (better with dead trees) but I really enjoyed this learning, thanks Team CEE
*Brilliant repair. We rarely use our hydraulic press as a sheet metal brake for the big stuff but you made that thing look like a ring roller lol. In Alaska a machine being out for a day might be a $20k loss but even parts that are helicoptered in from the closest FedEx station might take ten days to get here. As for the appearance, I've never met a lady yet who cared what the transmission housing on a Ferrari looked like.*
I love Kurtis' diagnosis: "The machine suffered an extreme case of gravity." Amazing repair.
Failures in gravity management keeps us repair techs in demand. Respect!
Newtons' first law of gravity was , it sucks, before someone changed it.
Lift operator;
Hey, It was Not my Fault, it was that "Gravity" guy. lmao
Did not know you could even try to repair Cast Iron with any torch.
Never even heard of "Flame Spray Welding."
Guess I need to get out more.
Yes quite a nice explanation, reminds me of my first nasty boating experience (broken propellor blades) the mechanic explained to me… “oh yes we get a lot of these type breakages all due to hard water”
@@michaelwellman2079 I know right? I have always brazed to do the repairs on cast but day-am that looked beautiful when he was done. Now I want a puddling torch.
40+ years as a welder/fabricator/repairman…I’m ashamed to admit that I’ve NEVER seen this process.
You can bet that I’ll be researching like mad!
Love your channel mate! Cheers!
YT abom79 he has many videos about flame spray buildups on shafting.
Flame metal spray has been used for decades to repair worn shafts or apply hard metal coatings. The trick is to preheat the parent metal. It’s risky as you can damage the underlying hardness.
Flame spray for shaft repairs has been around at least 50 years. I’ve never seen it used for welding. But the (relatively) diffuse heat makes good sense with cast iron.
I had never heard of it either after being in the business for 35 years
I've been welding 59 years and have heard of flame spray welding, but have never had the opportunity to see it done. Thank you so much for the concise explanation of the prep work and of course seeing the flame spray welding. Enjoy watching you work. Thank you from Dallas Texas
Well said. You come here to see some stuff and don't even know that you are learning something new. Great job Curtis.
I have to say, Curtis, from my perspective, you’re a young guy. But your skill and knowledge equals that of people in the business for much longer. I really enjoy watching these. And I thank your wife for doing such a great job with the shooting and editing of these videos.
I'm not positive but I bet he came up in the business learning from someone that cares as much as he does
I'm not a welder or fabricator, but i have been around a lot of it in my career. This is the first time I've ever come across powder welding...fascinating!
Well there you go, learning something new every day is what they say!
I first saw Eutectic at a training event in 1974. We had a play with a range of products, and i was fascinated by it.
Im a jouneyman welder and never seen this process before .
Everyday is a school day 👍
Same here! Never heard of a puddle gun in my 43 years.
It's probably one of those tools, not the kind of thing you need every day, but worth it's weight in gold when you do.
I can say, I've had to do quite a few cast iron welds in my time, fixing machinery mostly, and one of those guns would have saved a lot of swearing over the years.
I know you don't like being on camera but you definitely have a gift for explaining things so the average person understands it. I've never seen any sort of heavy equipment up close but you make it easy to understand what each part does. You truly have a gift.
I really think he needs an apprentice. Not necessarily to help, but to teach. And teach right.
How are we supposed to get any work done with all these bloopers! 😂😂
@@BabyMakR he's said before in his Q&A he has no desire to take on one - he just doesn't have the time.
Apprenticeship lasts for years. Initially just a gofer. Over time they take on more skilled work.
Sneaking up to the perfect fit is time consuming, but the results are well worth it. Outstanding work.
Awesome job.
Cheers mate thanks for watching
This dude is spray welding powder through a torch! How does he have the knowledge, experience, and established business of a seventy-year-old man at whatever age he happens to be? Curtis from cutting-edge engineering never ceases to amaze me!
haha thanks mate I just like to get in and give everything a go, never let textbooks get in my way of learning!
The skill to do comes from doing .😀😁😂🤣😃😎
@@CuttingEdgeEngineering I was introduced to spray welding in my first year as an apprentice, did quite a lot of different repairs with a eutectic Castolin torch, building up shafts, cast iron repairs and hard facing etc.
Determination and probably some shared knowledge from some old timers along the way.
As with all of us our trade gets better as we get older right up to the point where we forget how to do everything except tell the stories that go along with it. Hopefully young ears will sit and listen to our stories and collect some of the knowledge that we've learned over the years...
“That will do!” Are you kidding, that was pure brilliance! 👌
Each week I am in total awe at what you are capable of doing, and the fact that you and Karen take so much effort to share this with the TH-cam community. 👏👏👍😀
I totally agree, and Karen ain’t no fool- she probably makes a decent bit of cash by filming all this stuff for us appreciative viewers. 👌 I really love these vids, nothing is impossible if you believe you can !🏴
I used to use this method of repair on cast iron many years ago while in the automotive trade. I’m glad to see that in the right hands it still has its place in our modern world.
I’m so happy to see this almost forgotten skill still being performed by a truly talented tradesman. You’ve made an old man very happy. Thank you.
Having performed many cast iron repairs over the years all I can say is "Wow that puddle gun technique is impressive" and exactly what the Dr ordered for this repair. Great job fitting the plate and the follow thru, you are one mighty talented young-un! Want to bet that the owner / operator will just smile, pay your bill, reinstall the part and run the machine without ever replacing the housing? After collecting the insurance $ that is LOL! BTW as talented as you are you probably consider yourself "the talent" of this channel but I hate to tell ya that the dog and the wife are stealing your thunder! Oh well, "this is the way".
Hey mate, the missus and Homey agree with you 🤣 thanks for watching glad you enjoyed this, i'm thinking the new part would just go on the shelf as a spare 🤣👍
@@CuttingEdgeEngineering If it ain't broken don't fix it.
@@CuttingEdgeEngineering - I wouldn't have even ordered the part, but would have given you a bonus for a job well done saving me time and money.
i would still put the new housing. with the steel to cast iron you are asking for trouble long term. if it cracks later from vibration and you lose the transmission fluid is the insurance going to buy you a new transmission. i kind of doubt it.
I agree, the new replacement part will be still gathering dust on the shelf long after the machine has gone for re-cycling !
In my opinion I think this is one of the coolest repairs you've done
thanks Jeff appreciate it mate, it's a fun bit of kit to use
@@CuttingEdgeEngineering Yes, never seen that use before. Have done the bronze plate though, to fix up bores that were somewhat less than good, to get them to the point the shafting that ran in them, or at least the new shoulder bolts I used, would be a tight fit. Holes wallowed out, and the original pins were under 5mm diameter at the wear points. No way to get spare parts, seeing as the manufacturer, still in business, no longer supports a machine they made in the 1970's, and have less than a clue, though the parts likely are still on some of the modern versions, seeing as they likely use a similar version of the linkage. But the braze and drill was both faster and cheaper, and the shoulder bolt was $3, off the shelf. Now to get some flexible pneumatic cylinder shaft couplers for it.
I don’t ever want this channel to end. I could watch this for the rest of my life.
Not planning on stopping anytime soon 😎👊
I know right
The level of tools in your workshop is amazing....and the repairs thereafter are wow!!
And he still had to drag out the ol' high-tech ANVIL. Not too old, though, because it didn't have a clip-horn,
Great repair. Wished I had known of this method 40 years ago when I repaired my 1948 Willys L-134 block from a freeze crack. Cast is such a pain to fix. Seeing that grader hit the ground would have been a reason to kill or cry on the spot. Great repair job. Nice work as always Karen, and Homeless is still trying to steal the show.
Engine blocks are perfect for this sort of technique 😎👍
@@CuttingEdgeEngineering really hum 🤔so a 1970 BBM/iron hemi needs a new/taller 4140 deck/cam/reinforcements/modifying ( making a costume 1-off isn't in the cards for now plus im experimenting/R&D/working with a cheap boat anker aka polish a 💩to gold ) and id like the raze/fix the D-8 cast iron exhaust ports some and i have a investment cast SS shifter part out of a 2014 tr6060 transmission that needs some small tweaks/mods to work with my application and jb-weld isn't enough/cutting it even as a mockup/test fitment on my transmission bench.
so this gas method vs TIG vs stick which is the strongest/perment repair? and im sure pre slowly upto 1500F and after heating slow cooling is needed for both repairs? but i haven't done big cast parts like a block before or cast SS parts but have done small tractor iron junkyard scrap's as practice when i was first learning how to weld 20 ish years ago
and for usa 🇺🇸 localities a local welding supply can get the consumables? or call the place in Texas only for spay welding equipment? as i mostly do tig but have done other AWS welding methods like mig or gas rod it just isn't my favourite
@@richardprice5978 what language are you speaking?
@@cliveramsbotty6077 hah vary funny 😆you have to be trolling for the lol's 😂, that or you didn't see the flag 🇺🇸 or read the hole comment/real question i have
@@CuttingEdgeEngineering to add to the question does this gas spary work better for cast aluminium parts as well vs tig as some cast car parts like older transmission housing's and intake AL manifolds are really dirty/have a lot of junk in them are are hard to weld. and that one i did find out and on one of my per-1990's part's tig worked but look's like crap but my al welding doesn't happen to be the best but it's ok vs my SS steel welding technique's. and is there a replacement method that uses electricity instead of occ's / O2 & asenalene or natural gas?
I'm a certified welder and retired.. I used to do spray transfer welding on heavy parts for United Steel here in the US.. I'm very happy with the videos you are doing.. Keep up the great work you do.. The big boss Homeless should give you and the Mrs. A raise.. have a great weekend..
awesome mate respect to you, hope you're enjoying retirement 😎👍
Welding cast iron, such a nasty job that never turns out good in my limited experience. Was very nice to see you do it, really opened my eyes on what someone who knows a thing or two can do.
cast iron is very temperamental!
@@CuttingEdgeEngineering And that is on a good day.
Don't bother welding cast iron. Only lucky, or experienced people can pull it off, even when perfect tools are involved, and since this method ain't for everyone, learn to braze. Braze and cast iron go together like beer and pretzels.
In this instance, for example, brazing a T profile plug, would make the whole area stronger than original (also, same principles apply, you can put a dissimilar metal there, as long as braze can stick to it).
Back in the day, when brazing was part of the bread and butter, they used to braze steel strips over cast iron housings (think banding on a barrel) to make them stronger. I've seen housings from old, old Cats break crushers with this mod at the junk yard.
@@aserta Yeah, I probably would have gone with brazing in this situation. Much less chance of things going wrong and having cracks form later. Still Cutting Edge does good work so I doubt this thing will fail anytime soon.
Homeless is supervising, all good!
Recently found your channel and subscribed.
As an automotive fabricator for nearly 30 years I can appreciate the knowledge and skill you have. You are also a natural when it comes to explaining repair procedures and the video format works great, well done Mrs Camera person/Producer/Editor.
P.S I live in Staffordshire, home of the Staffy :)
Hey mate welcome to the channel!
Next door to Derbyshire- my home county. We have Rolls Royce. Staffs has JCB.
This is freaking awesome. Never heard of this type of welding. Love that you don’t limit yourself and are willing to do what it takes to help the customer. Great customer service is so hard to find anymore.
As always, great videography from the boss.
Regardless of what it may be, I will never tire of watching a true artisan apply their trade. With CEE you get it with both barrels, the engineering is first class and the video work is right up there as well.
What an absolute Pro !! He ran up, found the problem and then Curtis jumped in to fix it. Great camera work as well. What a fantastic team. Keep up the phenomenal content !
Ditto! Enjoyed watching.
That's a pretty cool way of doing it. I've had 966 loaders that guys have busted the housing on just like this and always used 99 nickel rod. Takes forever that way but it works, I'm gonna look more into this. You have imo the best machining channel on you tube btw!
I'd never seen spray welding used this way before. Very nice job! And the used-market prices for spray welding equipment just went up 10,000%.
A lost art if not already dead. Usually used for fixing broken things, but in our throw away society, just put a new one on.
@@paulkeys175 take er to the dealers
The job you did was very good. I never seen sold like this. I solder to in my workshop, but in a diferent way. Congratulations from Portugal 🇵🇹
Cheers mate thanks for watching from over there 😎👍
Ola amigo tudo bem.
Eu nunca tinha visto esse tipo the solda eu gostei ds forma que ele soldou.
Gostava de ver a forma que voce solda esse tipo de fetto fundido.
Um forte abrscao de Londres Inglaterra 🇬🇧
@@CuttingEdgeEngineering that welding technic is used every day in the factory I work here in Portugal. It is used to repair cast iron molds, it is a glass factory...
Love your videos....
I am totally addicted to this channel, which I have been enjoying for a year or so. My late father was a machinist and toolmaker; our shed at home was full of tools that I got to use during my teenage years. Sadly, I never got to run a lathe, but watching Curtis comes very close!
YOUR BRIEFING ON SPRAY POWDER IS INCREDIBLE TO ENCOURAGE PEOPLE !!!!!!!!!!!!!!!! THANKS !!!!!
Worked for a Cat dealer in late 90's before removing the engine on these motorgraders the shop foreman insisted on personally checking that all the trans/engine flange bolts were removed. Evidently some mechanics in the past were not very careful in removing ALL the bolts and broke an ear off more than once, to which the dealer had to end up paying for a new housing. Your workmanship is second to none!
I freaking love problem solving! I excel with problem solving when it comes to carpentry and rehabbing! It's the best feeling knowing you thought up a way to fix a big problem. Awesome job!
The customer is lucky to have you available to attempt such repairs. I'm sure it'll hold up and will definitely offset the cost of the parent machine down time. It doesn't look sh1t at all, for a cast repair, it looks amazing.
I've never heard, let alone seen, powder welding and it is a Fascinating process, along with your explanation as for the reason of it's use on this occasion AND the way your "cameragiggle" records it working, was brilliant. Always a joy to watch the videos and repairs by someone with numerous skills and able to explain the whole thing in a simple way. Wait to see and hear the "outtakes" at the end, always a joy
You always seem to have a really interesting problem to solve. A lot of thought even before the lot of prep. Awesome skills!
And Karen does a super great job of video and editing - big thanks to her too. All brilliantly supervised by Mr. HBB himself, or course.
Thanks mate we both appreciate the great comment!
Thank you for taking the time to explain how the "Puddle Gun" (is this the spelling?) works. Never heard of it before. A very clever principle, like a paint gun that paints with molten metal. Always see other people on TH-cam getting stuck when it comes to welding cast iron, but for CEE, it was just another day and another job well done. Kudos!
yes puddle gun! it's definitely a great way to do cast iron repairs
Great video. I've been welding for around 50 years off and on. This is the first time I have seen the puddle gun technique being used. That's quite impressive . I worked for a company that used a flame aluminumizing technique, but that was being used as a protective finish and not a structural repair. I would like to see more of this technique being used. Again , great video.
If it looks like shit, but works, it ain't shit. Great workmanship and knowledge.
I just knew that I was going to start seeing cracking everywhere and was amazed when I didn't. That was the best cast iron repair I've seen to date. that's why I tell everyone to watch your videos if there wondering how to fix something right. great job and great Video thanks for sharing
In the early 1980's I worked for STRATA welding. I used to sell a hell of a lot of spray powder gun kits and spray powder, mostly for cast iron repais. I notice that HARRIS also have a great kit. Good to see you still using this type of equipment.
done lots of cast iron repairs never seen this system before.i always found bronze rods and tig welding the best but this looks miles better.
That didn’t even look like it was a challenge for you. You made it look like a very straight forward, common repair.
Beauty is in the eye of the beholder. To the customer, that repair job looks like $$$.
I'm a machinist for a Cat dealer in the USA and spray welding is extremely common as part of out process. We spray weld nearly everything that needs material built back up. Even bearing areas and seal bores will get sprayed and machined back to size.
I wish our dealer here that I work for had it in house. Outsourcing is so sketchy
@@stevo450ify being able to do it ourselves is basically a necessity based on how much we do it. Yokes, pistons, brake anchors, duo cones, housings and hubs are the components I specialize in and everyone of them gets sprayed in one way or another to be able to recondition them.
Well done !! I first used spray welding in the early 1980s, in the USA. You did an excellent job.
I would only suggest 1 thing. In each of the corners I would recommend using a ¾ inch carbide burr for a radius. The same way drilling a hole at the end of a crack relieves stress, so does a radius. The metallurgy of the cast-iron housing
was of a high-quality with a high nickel content.
Lots of elasticity.
👍👍👍👍👍👍👍👍👍👍👍👍
Thanks for the tips!
I'm a welder/fabricator with experience in this kind of repair. I can tell you this is one of the hardest repairs to perform, depending on the material. Grey cast iron is a nightmare, ductile is a little more forgiving, and mailable is almost as easy as steel. It depends on the carbon and silicone content, the distribution of the carbon and the grain structure. I usually use nickel/iron DC TIG or Alum Bronze AC TIG. But to weld steel in to cast iron is very hard, they have completely different coefficients of linear expansion. Steel, when heated, will always contract more than it expands. Cast iron hardly moves at all when heated, so the end result is, if it doesn't crack again while cooling, then stresses are set up that cannot be relieved by post heating, meaning that when the casting goes in to service there is a strong likelihood of it cracking due to operational stresses from vibration etc. The only way I have had any success is by peening the welds after every weld pass.
Braising, electrode neg, peen. Cast is always a trash repair at best but doable.
Hi Darren Garden, Just curious, I have a backhoe. Circa 1989. Back digger section held on by top and bottom pins. The bottom pin section holding the pin snapped through on both sides and made a very loud crack sound. Brocken area is like rough sand and a grey colour. Its some type of cast moulding. Its one massive section that the backhoe arm swings from. I did a spark test, sparks are relatively small and stay closer to grinder and are a red type of colour. It ships off like small bits of sand compared to mile steel where it peals off when using chisel. Any idea on how to fix this issue as its holding a massive amount of weight. The ram rod also snapped off when this happened. I had only just replaced the other ram rod which also snapped. Was thinking it is some type of cast iron? If so, would a Ni 55 or NiFe work? Also wanting to weld mild steel on outside to help support it. Was reading that Ni Fe can be cold welded. Any ideas greatly appreciated as this part can not be replaced.
Oh forgot to mention, I only have a gasless mig and stick welder and propane torches. Also, would be impossible to heat up the part as its still on the machine and weights a massive amount. Part that broke off is 50mm high and 40mm thick. Broke off in two areas.
@@marinetrax I used to make excavator lift arms and buckets. They are made from carbon steel and should be welded with er70s6 otherwise known as a18 mig wire or rods. Although mig is not recommended and dual shield flux core is recommended. Full penetration welds. Pre heat is essential or you will get weld embrittlement and it will crack. You also should post heat to stress relive, but not essential.
@@darren-garden Thanks so much for your reply. Muchly appreciate it. Just to confirm, this is the section of the backhoe that the digger attaches to at back of machine. It has the breaks for the side shift and that holds the top and bottom pin. It is some kind of cast. I looked up to see what type of spark carbon steel produces and it says yellow. The sparks off this is more red and small. Not as small as cast iron, but the same colour as cast iron. And its brittle, peals off in sand like pieces and looks "sandy" grey. Do you still think that this is carbon steel? I was looking at using Ni 55 or NiFe welding rods and doing it cold weld as its impossible to heat up the whole piece as its a massive cast section. Thanks so much. I would post pictures for you but I cant on here. Thanks once again. Also, I don't have gas. I only have a gasless MiG or stick welder.
1/4 master craftsman, 1/2 artist, 1/2 teacher, 1/2 magician = 1 Wizard! I especially liked the bit at the end. Thanks from Delaware USA! 🇺🇸
That was an awesome repair you did on that housing. I’ve never seen it used for such a large fill. Well done Kurtis you are a very talented man, and the videography is second to none, great job Karen I love the videos. Peter😀👍🇦🇺
Cheers Peter glad you enjoyed it 😎👍🇦🇺
Brass has always been my go to for cast iron repair... This appears a bit less time consuming and less stress in the repaired joint due to brass pulling inward... Job well done...
Do you know if the (wet?) brass powder be reconditioned?
Nice work Kurtis, I'm impressed. I own a Victor spray welding system and never knew they had a version for seam welding. Slickest cast iron repair I've ever seen. Sure beats the high dollar nickel rod that rarely works and only makes your scrap more expensive. Thanks for the demonstration!
no worries mate thanks for watching
Yes, got some of those rods, and about the best use for them is refacing mower blades, as the metal comes out really hard, so takes a lot longer to wear out cutting grass. Last lot though I bought new blades, there was not much left of the old ones.
@@SeanBZA great idea! I (think I) got a box of hard facing rods on some big sale and figured I'd never really have any use for them. But building up the mower blade, especially on the Bush Hog would be a good use for them. Thanks.
Kurtis. I made my living with a torch for many, many years and I loved it. There is a certain personal satisfaction of taking something that's broken and bringing it back to life and useful again. I'm retired now but still miss working with my torch from time to time. Bill from Linglestown, Pennsylvania, USA.
GOOD GOD! What a way to "carefully" handle valuable equipment! Incredible job, Kurtis! And thank you for the flame spray welding lesson.
Fascinating job, well done. Your toolbox seems to have infinite capacity with a tool for every job. Great skills.
Definitely NOT your cut it close and let her rip everyday machine shop! SOO excited I found your channel. You are an ARTISAN in metals. You are so skilled with the work, set up of the lathe and know what to do to get results. I am so impressed and happy to see your videos pop up on my list. Some of the repairs you do well and beautifully make my head hurt looking at the initial damage but when you are done "VIOLA" it looks better than new! Your wife is a jewel (that you already know I am sure) and one heck of a videographer wow what some cool shots. As a photographer of 50+ years her cool use of filters BLOWS me away! WOW! As you can see over here in Mobile, AL in the good ole US of A I am absolutely lovin your videos, your wife's skills in shooting and editing the work. It's like going to class every time but way more fun than school I went to decades ago!
Please keep the videos coming you have fans far away and near too I am sure!!!
Hey mate thanks for the great comment and support we both appreciate it a lot! Always glad to read when a viewer is enjoying the videos, we plan to keep making them for a while yet. Cheers
In all my 50 plus years of welding, I have never seen this method of brazing. Absolutely beautiful job on cast. It doesn't matter the looks as long as it works. Thank you for the enlightenment of a way of welding.
What a great video! TH-cam has shown some interesting techniques to repair cast iron. This one is clearly the best i've seen yet. I love the attention to detail you demonstrated fitting that plate in so well. Another vote that the owner will NOT install the OEM replacement case if this repair shows to a permanent fix after a couple of months of use.
The repair looked exceptionally solid and if it didn't crack while cooling down, it should be permanent.
Not as if the part is going to be highly stressed during use. All it has to do is hold hydraulic fluid and provide somewhere for the pumps to fit.
It's just a sump when all is done
This was all about the right welding technique which you were all over like a cheap suit as a result of your experience. You and Israel at IC Weld are both great problem solvers. Every time I watch your videos I learn something.
It's kind of funny I see weld and cutting edge they're 180° apart and I don't mean by the world their personalities but they both can figure out any hard part to fix it hey and they both have a dog we have homeless and we have wylie E.
Isaac , his twin brother's not bad either , duh
@@gottahurt Isaac is a master at what he does, can you imagine what a team these two would make😀
@@rogerdavies6226 Yeah, not much talking, just a nod at each other and then on with the repair.
It was very impressive watching you ‘persuade’ that hefty lump of plate to fit such an awkwardly-shaped hole. I thought at first that you would trim the hole to as near a rectangle as you could get, but no, you went the more difficult route! Nice job!
I just came upon this channel as I am always watching anything that has good-excellent "Maker" content. This channel by far is the most diverse in terms of both types of work that is being done and also the most heavy-duty work being carried out to mend any broken machine in that part of the world. Additionally, he is a very good communicator with detailed explanations of why and how about everything the does and is just a pleasure to watch and learn
Great Job! I know it´s kind of hard to get information on parts once they leave the shop but still I´d love to see a follow up on how the housing is holding up in every day use. cheers
We will try and get an update!
@@CuttingEdgeEngineering I think so many people are looking at your content, and will be for many, many years, that updates on this and any other projects would be really great. You could even do a project updates video with a commentary perhaps? Reading through all the comments here makes it obvious how much you are giving and sharing to the global community. It makes me think of my Dad, who not long before he died lamented that so much knowledge and experience was going to be lost. You are certainly creating a legacy and making the world a better place for many, many people. Thanks for this.
That was an interesting repair. Job well done and tad nicer than JB Weld :)
Do love that jb weld has saved my bacon quite a few times.
Nicely done, very wise drilling a hole on the end of the crack, definitely helps stop the crack extending.
On the same note.. would there be any gain in having a curve on the corners of the repair rather than a squarish corner... I know it is just a short term repair.. ????🤔🤨😀😁😎nice job.
@@rodmills4071 They’ll use this until the new piece gets delivered, & then continue with this one so that the machine can work, if it works don’t stop.
There’s nothing more permanent than a temporary repair.
Yes, I agree a curved corner would probably be better. Over the years I’ve done many similar repairs and I’ve found from experience a hole drilled on the end of a crack definitely prevents the crack from extending. In my day we only had brazing or electrodes, this new powder technology is a big improvement.
Short term repairs often become long term repairs 😂😜🤪
For a young guy, you sure have an enormous wealth of skill and knowledge in your field. Good on ya!.
I like these kind of videos. In the late 80s I heard about this process in school. Later in the early 2000s we had an axle housing repaired in this way. But I've never seen the process myself. Today I saw it for the first time, for which I thank you. I hope to see many more special repairs.
awesome mate glad you could watch and enjoy
Brilliant repair, you never fail to amaze me with your range of skills and understanding of what is required to get a job done properly-no cutting corners. That repair will outlast the machine, the owner no doubt will keep the new part just in case ‘gravity’ strikes again. Fantastic all round team effort. Greetings from Tasmania Australia 👍😁🦘
Simply amazing work, Kurtis!! I'm sure the owner of that machine was elated to save 3 1/2 months of productivity! Even if you charged him triple, he got a BARGAIN!!
Outstanding ! Your complicity with your customer is commandable ! Well done !
Absolutely amazing work Kurtis. Well done and I've learned the advantage of using a puddle gun verses a standard spray welding system.
always welcome mate thanks for watching
This is amazing. I'm a student welder / fabricator and have never seen this process before! Will have to ask my instructors about it! Looks really good, fast and effective!
I learned this process for engine casting repair for cylinder blocks and heads used a huge thermal cleaning oven for preheat of huge industrial blocks and heads there is good money in being able to do it
Great job! I knew of spray welding for shaft build up but never knew of this. Ive done the same type of work you do for most of my career. But you always come up with something I can learn from. Thanks for the video!
I used to use the castonil eutectic (spelling might be out but amazed I even remember that much, was a long time ago!) Powder to build up shafts. I guess it did what was required but it's actual strength in tension was terrible.
Hi, thanks for the demo on spray welding. As a teenager in the '60s growing up in Texas I had a summer job refurbishing oil well equipment(nasty work) only heard of a guy with a travel unit to do spray welding on worn down drilling shafts. Made good money back then. Your demo is the first time I have seen it done after all these years. Thank you.
Quality repair. Wouldn't be surprised if that "temp fix" becomes permanent.
It would be interesting to see how this repair lasted in the long term. With global supply chain issues, this could be in place for a year or more. Love the paint to finish the job. Always professional.
haha yeah will have to get an update from the customer after the new one arrives
@@CuttingEdgeEngineering Going to bet it will still be on that machine in 5 years, still perfect, even with the rattlecan intact.
That has got to be one of the most impressive repairs I have ever seen. Hats off to ya!!
An electric and gas welder from Russia is retired. I watched it with great pleasure. Thank you for your work!
Man I love to see the old school spray welder come into action! It’s such a cool process to see. My dad was so good at this. He could repair any shaft that got out of round from a bad bearing or race etc and lathe it out to fix an obsolete part. Really cool to see it being done in this manner
Wow, this powder gun really deposits some metal. Indeed a real different system from the eutectic I see Abom using sometimes.
This brought to mind a funny case from when I worked in a factory. We had state of the art Kemppi welders that could also weld aluminium. One lad thought he'd have a go. Put all the right settings and went to town. We had a good laugh while waiting to tell him that he forgot to change the stainless steel wire for something more suitable. I learned some new bad words.
he thought he was going to nail that repair 😅
now I'm curious what happens when you tried that... explosions on smaller scale??
@@g60force The aluminium just melts away while the steel wire balls on top of it. Makes quite a weird sound.
of course what you do is amazing, but your camera work and video editing is also excellent. Tks for uploading.
Never thought this possible you definitely learn something new everyday really impressive repair well done bud
Unbelievable workmenship!!! I love your one man band approach. It's amazing what you do. Your wife is an amazing cinematographer also! I can't wait for your videos. Even for a home machinist many of your techniques can help with hobby work!
Thanks for the great videos!!
Brilliant repair! And by coincidence, I was cleaning out an old cabinet at work a few months ago and came across the Eutectic version of your UTP flame spray welder. Now I know what it is and what it can do.
awesome mate
With 35 years in the automotive repair industry, I have come to understand the difference between knowledge and Skill. Both have a genuine place in the repair industry but rarely seen in the same place at the same time. Hearing your opinion and how it was based on experience was refreshing. No bashing of other methods or skills, just preference based on experience. To watch your skill in completing the job was just as enjoyable. Having worked in the mining industry for a short period of my life I have a basic understanding of the reasoning behind your repair choice. I do have a question. I do not repair cast iron often as the kind of repair i am doing now rarely requires it. When required it is usually limited to thread repair. I am not a welder by trade so my question may seem dumb to you. Recently I was advised to use a bronze wire and a stainless wire twisted into one wire for filling a crack coming off a bolt hole before thread repair. it was a bit tough to get the mixture to flow into the termination hole for the crack. The rest of the filler material flowed correctly into the ground out area. I know it is tough to answer without seeing the issue first hand but your opinion as to what i could have done wrong would be welcome. In context I have never had a issue with straight bronze filler rod.
I remember years ago reading an article about "stitching" a cracked cast iron engine crankcase together after a catastrophic failure. The solution was to drill a series of holes on either side of the cracks then use "flat wire" to join them. Some brazing then took place to seal the join permanently, whilst the wire remained as a reinforcement. The article had several artistic photos of before and after. It seemed a legitimate solution at the time (possibly 1960's or so).
Here is a video about that: th-cam.com/video/Pq0wfU4ZaKk/w-d-xo.html
@@KW-ei3pi Yes, I was fascinated by that more modern version of what I read about. It seems to be a big business, but very tedious compared to what we saw on CEE's latest episode.
I have seen land cruiser heads "stitched" like this . It was 40 years ago. Don't know if it's still a thing.... 🤔🤨😃😎
metal locking has been done for a long time. there is no welding or brazing with that method. i was at a shop that did that and they were fixing a locomotive engine block that put a rod through the side. they actually had an old block as a donor and using a 3/8 drill they " cut out" the section of donor block and broken block and stitched the part in. it was a 20k repair 22 years ago.
@@ronblack7870 No wonder it was expensive, it's a very time-cosuming process, with a lot of precision fitting of awkward shapes.
I've done this since I was 25, when I worked for Eutectic in Switzerland. But we made sure to preheat the whole part when repairing cast-iron parts, and slow cool in vermiculite. Kurtis, I think you were a bit lucky that it didn't cracked, but hey, the part was salvaged...
The cooling down is where the trick is, damn I hate cast iron lol
We found better systems than EnDOtec DO*23 ! How much CI welding have I done, try 45 ~ 60Kg per month, for the last 35 years.
I think he didnt want the heat affecting the hydraulic ports so he gambled and localised the heat. Good repair and customer had nothing to lose just Curtis if repair failed
Brilliant repair and video guys!!
Had only ever seen spray welding done on a shaft held in a lathe.
Again, thanks for taking the time to go through what the tool is and WHY it is being used.
Hey mate! Glad we could show something a bit different for viewers, always good to know if people are seeing or learning something new. Have a good weekend mate
I've had cause to repair cast iron in the past (stick, brazing, stitching with threaded stock etc but all I can say after watching this is "wow"... I've learned something today. That puddle technique with that gun is nothing short of amazing. Your customer is very lucky.
Thank you very much for posting that.
Really like the tight control with the spray. The others I have seen spray all over the place. Very effective use of CAD ( Cardboard Aided Design ). The repair looks solid, hopefully the customer is satisfied. On the lighter note, that tail of Homeless can be a lethal weapon once he gets it going.
CAD term you use joking suddenly got me thinking in this digital age...
could be scanned then there's even 3D metal printers that fuse powder
so you could get like 99% perfect fit, but it's obviously more time-consuming!
Cardboard aided design 🤣 that's brilliant!! I came up using cardboard patterns and timber sticks to design machinery ROPS cabs. Works like a charm!
@@TheLazerhorse For ultimate CAD have a look at Bad Obsession Motorsport's Project Binky series, the ultimate expression of the art, oh and a few brackets lobbed in there too!
@@JonTheBrush you might even go so far as to say that the Binky project is all "AutoCAD"
Cardboard aided design is great as long as the cereal boxes are empty first
Really annoys the missus if the frosties box has a big hole in it
I admire how you didn't overdo the grinding. It needs to work for 3 months, its good for the repair to be visible through the paint, more grinding = less strength, just grind enough to make sure nothing gets loose inside the oil reservoir and to get good paint adhesion on the outside = perfect.
Dude, that was awesome. I’ve never actually seen that done before. It sucks you even had to do it though. I feel bad for the man whose grader was damaged in transport.
I've done such repairs more than forty years, never had the equipment or technique to do it anywhere near so well and clean. Thanks!
That was absolutely amazing. It looks like brazing with powder basically. Looks like it did the job to me. Great work!
Fascinating demo of the spray puddle gun! I've seen spray welding but this is an interesting variant. Love to see more - that was a great repair and well worth it. Nice work creating the patch - smooth and efficient.
hey mate thanks for watching glad you enjoyed it, we will be sure to show it again if we get another good repair
Sick.
thanks for watching!
Freds Fabrications uk ,love your vids ,been self employed 3 year after kidney cancer ,35 year in industry and just picked up a Fortargen flame spraying kit very similar , i`ve had 90% success on 80 odd jobs but last 2 was a right mare , so will be trying this method , keep up the good work , i did 6 years in a place making loader shovels and telescopic handlers Matbro uk tetbury in the 90`s and was mainly stress relieving , lining all the bosses plate up after welding and overcoming the distortion , all the best fred just watched the vid again and the case and pots looks exactly the same ,megga
I work with aluminum, stainless and titanium and stay away from cast iron because I've never had good luck with it. Awesome skills you have, you made a very difficult repair look easy. Great video, please keep them coming. All the best from 🇨🇦
Guess it’s daytime there but it’s 2am here, love watching your videos on my break, definitely makes my night go by faster...
The time difference blows our minds. 5pm Friday now for us!
Same time where I’m at. I just got home from a long day at work, just in time to relax and watch this new video. Looks interesting. I’ve always been interested in this type of repair.
Brilliant job! Yeah, Alaska is about 2245 hours right now.. just finished digging through some frozen ground, but had to get in some CEE time before getting some sleep! LOL Back at it at 0500 hrs!
@@CuttingEdgeEngineeringYeah it’s pretty crazy isn’t it, that was an interesting repair, I hadn’t seen that particular type of welding before, I’ve seen the spray welding it not that, looking forward to the next one, thanks Kurtis
Kurtis, you remind me of my grandfather, he was a machinist, welder, black smith. I helped him in his shop. People would come from all over to get repairs done that on other shop could or would do. I enjoy watching you work, I miss him a lot, he passed 29 years ago.
Enjoying my morning coffee, watching my weekly Cutting Edge Engineering video and damn you every time they're more interesting! Never knew spray welding until I saw Abom79 doing shaft build ups, and now here you are using the same sort of method to actually weld something! Never to old to learn I guess! Great video as always. Take care guys👍🏻🍺
Good morning mate glad you could watch and enjoy 😎👍
Fantastic job Kurtis, I’ve never seen a repair undertaken like that before. Why would the owner even bother replacing your repair job with a new housing?
I love how he takes so much pride in his work I work the same way. It drives me insane how I get rookies to train at work and they don’t take pride with the quality of work they do. Awesome to see someone else this way. Nice job man. Coming from USA 🇺🇸
It pleases me when I see that a part is being repaired with appropriate means and techniques. The craftsmanship is excellent. In Germany we say: The welder fills everything under an inch. Greetings from Germany!