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




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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