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Welding Spherical Rod End on Shaft

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  • Welding Spherical Rod End on Shaft

    My customer is in the process of restoring a vintage Karmann Ghia. He required a push rod for the master cylinder. He couldn’t purchase the correct part, so he bought one that was too long. He cut off the end of the shaft to make it the correct length and requested that I weld a ball back onto the end of the shaft. The top view in the following shows a Xerox of the correct shaft. The bottom view shows the shaft that was too long, which had been shortened. He wanted me to weld a ball on the end of the shaft that looks like the Xerox picture.

    1. Shaft that requires a spherical rod end
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    2. Me welding a ball on the end of the shaft
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    3. Ball as welded
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    4. Grinding a rod end
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    5. Rod end all done
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    -Don
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DoAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    Would it have been easier if he cut a chunk out of the middle of the one that was too long and then had it welded back together instead of welding just a ball back on the end? At first I thought so, and now I don't know if it would make much difference. You'd have a much better idea.

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    • #3
      Might have been just as easy to machine a new one from bar stock, eh Don? You would’ve had to grind the living daylights out of some HSS too!

      Comment


      • #4
        Originally posted by MAC702 View Post
        Would it have been easier if he cut a chunk out of the middle of the one that was too long and then had it welded back together instead of welding just a ball back on the end? At first I thought so, and now I don't know if it would make much difference. You'd have a much better idea.
        I’m not sure exact what the customer did, because there is evidence of welding in the middle of the shaft. My repair was actually pretty easy, I just built up the end of the shaft with weld. I used enough heat to keep the weld bead spherical in shape.
        Click image for larger version

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        -Don
        Smith Oxyacetylene Torch
        Miller Dynasty 200DX
        Lincoln SP-250 MIG Welder
        Lincoln LE 31 MP
        Lincoln 210 MP
        Clausing/Colchester 15" Lathe
        16" DoAll Saw
        15" Drill Press
        7" x 9" Swivel Head Horizontal Band Saw
        20 Ton Arbor Press
        Bridgeport

        Comment


        • #5
          Originally posted by ryanjones2150 View Post
          Might have been just as easy to machine a new one from bar stock, eh Don? You would’ve had to grind the living daylights out of some HSS too!
          I could have machined it from a solid bar. I do have carbide radius cutter bits for the lathe.

          -Don
          Last edited by Don52; 12-19-2022, 12:35 PM.
          Smith Oxyacetylene Torch
          Miller Dynasty 200DX
          Lincoln SP-250 MIG Welder
          Lincoln LE 31 MP
          Lincoln 210 MP
          Clausing/Colchester 15" Lathe
          16" DoAll Saw
          15" Drill Press
          7" x 9" Swivel Head Horizontal Band Saw
          20 Ton Arbor Press
          Bridgeport

          Comment

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