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  • X-Mark Mower Deck Repair

    My customer broke off the right hand bracket that supported the mower deck. I believe that the problem was that at some point in the past 5 years he hit something hard. Figure 3 shows a force diagram which would explain the dent that I observed in the top of the mower deck. The first step was heating up the dent and pounding it out against a large piece of steel.
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Name:	1. Mower deck bracket.jpg
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Name:	2. Close up of broken bracket 2.jpg
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Name:	3. Force diagram.jpg
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Name:	4. Dented mower deck.jpg
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Name:	5. Dent heated and pounded out.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
    The 1/4" support bracket was broken off clean and also had a crack about halfway through. I grooved and welded up this crack first so that the bracket had a chance of sitting flat on the mower deck. Next I clamped the bracket straight and pulled in the bottom of the bracket flat on the mower deck. It looks like a lot of clamps, but I added them one by one until the bracket was exactly where I wanted it and straight. I welded up the spider cracks and then tack welded the bracket in place. Next I welded up the groove in the 1/4" plate of the broken bracket to the piece still attached to the mower deck.

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Name:	6. Crack in bracket welded up.jpg
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Name:	7. Clamped for tack welding.jpg
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Name:	8. Spider cracks welded and tacked in place.jpg
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Name:	9. Tacked straight and ready for welding .jpg
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Name:	10. Groove welded up.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

    Comment


    • #3
      I added an additional bottom plate for additional support and hopefully to help stop denting of the top of the mower deck. I added an additional weld to attach the bottom plate of the broken bracket to the sides of the mower deck for good measure. I decided to beef up the 1/4' plate that broke with a fish plate, which I set back from the edge of the original 1/4" plate by about 1/5". The last step was priming and painting it. My shop was 50 degrees F so I used my 1000 watt shop lights and my 800 degree heat gun to help the paint to set up before we reinstalled the deck on the tractor.

      -Don

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Name:	13. Fish Plate added.jpg
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Name:	14. Primed and painted.jpg
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Name:	15. Close up of welds.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

      Comment


      • #4
        What is the "gun" in the last two pics? I am not familar with it. Is it a type of powder coating system or heat gun?
        A FEW OF MY TOYS !!!

        MX Linux
        LinuxMint

        Miller Roughneck 2E
        Lincoln Weldpak 100
        Gianttech Arc 200
        Victor O/A

        Comment


        • #5
          Originally posted by smawgmaw View Post
          What is the "gun" in the last two pics? I am not familar with it. Is it a type of powder coating system or heat gun?
          It’s just a heat gun.

          -Don
          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


          • #6
            Originally posted by Don52 View Post

            It’s just a heat gun.

            -Don
            That was my first guess. I just was not sure.
            A FEW OF MY TOYS !!!

            MX Linux
            LinuxMint

            Miller Roughneck 2E
            Lincoln Weldpak 100
            Gianttech Arc 200
            Victor O/A

            Comment


            • #7
              Did you stop drill the cracks running all over the place?

              As usual, excellent job documenting the repair.

              Comment


              • #8
                Originally posted by ryanjones2150 View Post
                Did you stop drill the cracks running all over the place?

                As usual, excellent job documenting the repair.
                I'll second that. Don, your pics and explanations are really great. And nice work, too!

                Comment


                • #9
                  Originally posted by ryanjones2150 View Post
                  Did you stop drill the cracks running all over the place?

                  As usual, excellent job documenting the repair.
                  Perhaps I should, but I don’t typically drill the end of the crack. When I grind out the crack I always grind beyond the end of the crack a little. I also start welding at the open end of the crack and weld towards the closed end, so the weld will have good penetration at the end of the ground out crack.

                  -Don
                  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

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