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Welding Aluminum Bracket for Ancient Dump Truck

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  • Welding Aluminum Bracket for Ancient Dump Truck

    During disassembly by mistake my customer broke off the ear of the bracket, because he didn't see the last bolt. After I cleaned up the casting I noticed that there was a second crack. I grooved out the 2nd crack from both sides for 100% penetration and filled it up with weld. When I was grinding the broken off ear, the carbide burr caught it and threw it from the vise, never to be found again, so I had to make a new one. Fortunately I had the welding and machining fixture done by that time, so I new where to locate it. The following pictures document my progress.

    1. Cracked Bracket
    2. Cracked in two places
    3. Outside of 2nd crack
    4. Inside of 2nd crack
    5. Making welding and machining fixture

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Name:	2. Cracked in two places.jpg
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Name:	3. Outside of 2nd crack.jpg
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    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    Here are some more pictures:

    6. Bracket mounted to fixture
    7. Making new ear
    8. Carbide burr to bevel casting
    9. Standoff for welding ear
    10. Spotfacing excess weld

    Click image for larger version

Name:	6. Bracket mounted to fixture.jpg
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Name:	7. Making new ear.jpg
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Name:	8. Carbide burr to bevel casting.jpg
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Name:	9. Standoff for welding ear.jpg
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ID:	590392

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Name:	10. Spotfacing excess weld.jpg
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ID:	590393
    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

    Comment


    • #3
      Here are the last two pictures.
      I will try to get a picture of the truck when I drop off the repaired bracket.

      11. Bracket welded and machined
      12. Close up of welds

      Click image for larger version

Name:	11. Bracket welded and machined.jpg
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Size:	79.8 KB
ID:	590395

      Click image for larger version

Name:	12. Close up of welds.jpg
Views:	1
Size:	88.2 KB
ID:	590396
      Miller Thunderbolt
      Smith Oxyacetylene Torch
      Miller Dynasty 200DX
      Lincoln SP-250 MIG Welder
      Lincoln LE 31 MP
      Lincoln 210 MP
      Clausing/Coldchester 15" Lathe
      16" DuAll Saw
      15" Drill Press
      7" x 9" Swivel Head Horizontal Band Saw
      20 Ton Arbor Press
      Bridgeport

      Comment


      • #4
        Looks like something the customer tells you will take ten minutes to fix.

        Comment


        • #5
          Originally posted by MAC702 View Post
          Looks like something the customer tells you will take ten minutes to fix.
          And 4 hours later your finished. Real nice work that should hold for another 30 years. I like the plate (fixture) to keep it all lined up.

          Comment


          • #6
            Originally posted by Oldgrandad View Post

            And 4 hours later your finished. Real nice work that should hold for another 30 years. I like the plate (fixture) to keep it all lined up.
            You are absolutely right, it would have taken four hours, except when I bevel ground the ear in the vise, the carbide burr caught it and sent it to an alternate universe. I looked for it without success for one hour.

            I used the plate to hold everything flat and in location while I welded it. The riser tube on the left hand screw allowed me to weld the ear to the bracket, while it was being held.
            Last edited by Don52; 06-11-2018, 03:39 PM.
            Miller Thunderbolt
            Smith Oxyacetylene Torch
            Miller Dynasty 200DX
            Lincoln SP-250 MIG Welder
            Lincoln LE 31 MP
            Lincoln 210 MP
            Clausing/Coldchester 15" Lathe
            16" DuAll Saw
            15" Drill Press
            7" x 9" Swivel Head Horizontal Band Saw
            20 Ton Arbor Press
            Bridgeport

            Comment


            • #7
              Don't worry you'll find that piece, in a year or so.

              Comment

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