Welding Aluminum Bracket for Ancient Dump Truck

[Don52]

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

[Don52]

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

[Don52]

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

[MAC702]

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

[Oldgrandad]

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.

[Don52]

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.

[Oldgrandad]

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