10 ton mega welding repair job finished! 12 rolls of wire ! my 500th video! engineering machine shop

massive thanks to Karl Casey ‪@WhiteBatAudio‬ for the awesome synth industrial tracks
PART 3 THE END!!
CHECK OUT PT 1 & 2
after 3 months of disassembly, gouging air arc welding, stress relieving , normalisation, heat treatment , machining , re assembly -- it's back to work! the epic conclusion to my mega project. lots of machine work in our engineering workshop with giant borer and milling machine.
then we get to see the jaw crusher crushing rock in the quarry.
#engineering #welding #brutal #cutting #gouging #crusher #rockcrusher
other great channels to check out
‪@weldingtipsandtricks‬‪@snowballengineering‬ ‪@DieselCreek‬ ‪@welderfabber‬ ‪@WhiteBatAudio‬ ‪@CuttingEdgeEngineering‬ ‪@ICWeld‬ ‪@ProjectFarm‬ ‪@AndrewCamarata‬ ‪@bruceinaus‬
check out part one the strip down and weld preparation...
• HUGE welding repair st...
the insane preheating begins after insane amount of preparation to get to this point! to lots of air arc gouging,grinding welding heavy lifting with crane in our engineeringworkshop.
the final part of this repair shows a stack more tlstrengthen plates, then heat treating and also 120 ton boring machine and giant lathe, then I get to go see it on site crushing rock after it has been returned to work. so make sure subscribe if you want to see the final part thanks guys.
we specialise in big jaw crusher and cone crusher repairs UK wide. even big impactors. we fix everything from excavators , loaders, dumpers ships wind turbines big hydraulic rams, you name it we fix it
thankyou everyone for the awesome comments on part one of thos video, you guys rock!
comments are my favourite part of KZbin!!
check out our Facebook page for incredible photos of past projects..
/ cookebrosengineeringltd
for UK engineering..
www.onwardengin...
/ allistairc123
other awesome engineering welding channels..
cutting edge engineering
welder fabber
Icweld
in honour of men like my dad, Sammy and Fred that have gone before me..
vm.tiktok.com/...

[@ICWeld]

Incredible repair. Way bigger than anything I have ever done! Nice job man.

[@allistairc123]

Thanks Issac, I have complete faith you could do it if it came your way brother. I love your relaxed methodical outlook on jobs, you remind me of every great old boy I learned from👍🏻👍🏻 Patience. Stay safe live long! Good to hear from you 👍🏻👍🏻

[@siongriffith1505]

Congrats on the 500 videos, and that's some amazing heavy meatalwork there!

[@charlesfeltham8528]

What amazes me most with this man is not just his welding skills and his knowledge of strengths and structure but also that he has the ability to clearly explain what he is doing and why he is doing it. Great work my friend. He always explains his thinking throughout the process so others learn not just how to do the job but also how to THINK about it. Once again, AMAZING, keep up the good work.

[@JT-si6bl]

Comfortable in his skills, and with them. Stuff of legend. Maker of new worlds.

[@RichardVogler-e4y]

This repair has to be one of the most amazing ones I've had the pleasure of watching. As a fellow repair welder, my hat's off to you, sir. Job well done

[@JohnComeOnMan]

Can we all give this welder some credit for fantastic editing! The time-lapse/music sequences were mesmerizing.

[@alexannal]

Love this channel. Congratulations on 500 video. Brilliant seeing heavy engineering. For some reason I can just watch people welding for hours

[@TonyGingrich]

I just binged all 3 videos of this project. Inspiring work! This made me miss my younger days as a millwright. Never had a task quite this large, but I was nonetheless taken back to some of my own moments of triumph. Thank you for sharing!

[@whathasxgottodowithit3919.]

Great video as always, it is amazing how it holds together long term when in operation with all the vibrations and loads on the components, You have completed an outstanding job there. Just shows how important Heat Treatment is to the long term durability of the equipment.

[@tonyktx44]

I really like the way you wear your safety gear during production. It really helps train young welders proper procedures. Bravo on a well done HUGE project.

[@clarobert]

Congratulations on 500 videos from the middle of the US. Great work - your editing has evolved over that period as well. Hope you keep bringing us incredible videos of monumental repairs and work.

[@ChrisDoll44]

I love the fixin' community on KZbin. All of you guys are a pleasure to watch. Happy to be a viewer of a great majority of those great channels you mentioned.

[@jamesdrake2378]

I cannot think of another person on all of KZbin who burns more wire than you. Thanks for the content and greetings from the NJ Bayshore. On Fire Welding is doing a nice job as well.

[@I_Dont_Answer_Questions]

Solid repair as always. What's with the trumpard sign? Sarcasm?

[@davidquirk8097]

Great job! That's an amazing piece of work and great to see the machine in action again too. Thanks for showing us the large borer too. I'd love a company history video with some focus on the machines in your machine shop. There's very obviously a story behind some of that kit.

[@garyyorke1080]

3 hours of awesome content . Very worthy of being a pivotal number in the playlist . Well done on reaching 500 that's really being dedicated to your interest in capturing great subjects to share . Really loved this 1 and brilliant you could get the footage of it actually working and doing what it does best . I can only guess how chuffed you are that all the hard work behind the scenes on this one paid off as you said in the first video you had all the organizing to do from collecting to delivery including the weld compatibility testing and every thing in between . A long winded job for you of many many hours of prep and preheating before the many hours of actually welding . Loving the engineering videos and obviously these big projects the plant repairs are my personal favourites as it shows how easy something can get broken regardless of size . As I.C weld once said thanks to the idiot operators they keep him in work repairing their mistakes ..many thanks for sharing this project and someone tell the guy in the comments your Irish not Scottish

[@hfdzl]

This is one massive jaw!! You are getting to be a legend here on KZbin as far as I am concerned!! Attaboy for 500! Ran crushers for years what a soothing Zen sound and rhythm!

[@KW-ei3pi]

Awesome job. Editing video is a HUGE job. And getting it right is difficult for someone who is not a professional video editor. Music is a whole other can of worms, and getting it right is very difficult. I'm just into the section that begins at 15:00, and I just had to stop and say what an awesome job that you did with the music and editing. It is just amazing and I think it would make a good standalone music video or an intro to your channel. AWESOME !!!

[@BoWallenUSA]

Congratulations on a fantastic job done.⭐⭐⭐⭐⭐.You definitely have a ton of skill, experience, and patience. I have years of experience using and feeding those machines in the 70's and 80's, which led me into repair and maintenance. Carry on, please; I love your style and videos.

[@buynsell365]

OMG what a AMAZING repair seires !!!! .......... I could not stop watching it.............Excellent job.

[@jamesbieniek8290]

Good job on 500. I love these major welding jobs you get into.

[@mikeaustin9810]

Congratulations on 500 videos. You do such great work on all these big projects that you do. And on that cordless welder I don't think they make that yet, but I heard they're making a cordless extension cord so that might help you until they get that cordless welder done .LOL thanks for the great content . Here's to 500 more videos🎉💪🙏

[@stephenvale2624]

During my career I always just pushed electrons for a living. And that mostly at a desk in an air conditioned office. Seeing these welding snd machining videos is an absolutely fascinating glimpse into a much rougher tougher job than I have ever experienced. Many thanks for the sharing and educating that you do!!!

[@rowycoracing]

Very impressive repair job. Nice work! Thanks for posting this series, it was quite interesting to watch. Seeing it at work at the end was very cool.

[@PeterChapman-rg6gr]

It puts most of the KZbin so called repairs to shame. We have a few genuine repair channels and hundreds of click bait pure bodge channels.

[@DMSparky]

As a sparky I can tell you with a resistive load like that 1VA is 1 watt. VA is volt amps. Watts = volts x amps. So 150kva over x 5 hours is 750000 watts of electricity or 750kwh. Did they have a diesel generator outside? According to a random website diesel generators use about 0.4L per kilowatt, so that would be at least 300L of diesel burnt.

[@allistairc123]

Awesome numbers thanks bud

[@7333-e3k]

Absolutely phenomenal series, thank you so much! Thanks for taking us on the journey and all the extra footage! Keep up the great work, both in the amazing work that you do and in documenting it for others to see!

[@Tinman97301]

As an operator I can't thank you enough for taking pride in your work. The job quality from people like you is more noticable and appreciated then you know. Someone like you makes the difference in my day. Thank you.

[@boydovens4180]

A very challenging problem to put it mildly , the shear size and weight alone made it seem impossible . Getting information on the best way forward was brilliant and correct , the shear mental battle of taking on this project is truly exceptional . Many would have said no , but you have proved it can be done . A small tip the wire feeder , the Brass bushes in the rotating gear are to soft , try getting them machined out and re bushed with a material like Phosphor Bronze they will last a lot longer .

[@b2dmastersniper]

Hi Allistair - loving your content. I live in BC- Canada and own a shop with some waterjets, some cncs and other fab equipment. I also design and build custom machinery for many industries. Your content is superb and right up my ally. I love seeing the heavy steel, I get excited anytime we are cutting anything over 100mm thick on the waterjets. That horizontal boring machine in your shop is a thing of beauty, an awesome piece of engineering built to last. I love to see your enthusiasm for all aspects of the job and showing the whole project from broken beginning to operational end is very satisfying. Keep up the good work!!

[@joshualau7982]

yo what area of BC?? I'm in the Fraser valley area :) i worked in mission for a bit.

[@b2dmastersniper]

My shop is in Langley @@joshualau7982

[@garymucher4082]

I can't even believe that something large and extremely demanding would be able to be welded back to working condition again. And equally so, I can't begin to imagine the massive loud noise in that building while it is running. Thumbs Up sir for a great series and seeing how you put it back together.

[@juyfjgfjhgfjugf4702]

I REALLY LIKE THE MACHINING CONTENT,THANK you

[@Mudsuitable]

Honestly this series is one of the coolest things I've ever seen, its mind boggling how it all went together and what the end result has to endure. Excellent work my friend!! You have my respect!

[@OldePhart]

LOL . . . size of a Microwave, Donkey... out of respect for us yanks who will use anything but the metric system :)

[@skwerlz]

I always love watching your large repair projects like this, partly just in case I end up doing something similar but also so I can sit back and say "at least I didn't have to do THAT." Anything and everything with respect to the welding and machining, planning process, etc... is more than welcome in my book. So glad you got to go see your work in action, for me there's always a feeling of pride and accomplishment when I see my work installed and operating. The operators were totally cool as well for going out of their way to give you the shots they did.

[@blahfasel2000]

Interesting to watch. As for the heater power, 150 kVA (or 150 kW since heaters are a resistive load) sounds about the right ballpark. Steel has a heat capacity of roughly 0.5 kJ per kg and Kelvin, so to heat up 10 t of steel by one degree you need about 5000 kJ. 150 kW delivers 150 kJ/s, so about 33 s to deliver those 5000 kJ, or in other words with that power you could heat up the crusher jaw by just under two degrees per minute or 550 degrees in five hours. Of course that ignores heat loss to the environment (and other details like that the heat capacity isn't completely constant over this temperature range), but I think that cancels out with not the entire jaw being brought up to full normalizing temperature either.

[@allistairc123]

Awesome figures bud thanks for that insight

[@ruthbees7214]

Well done at 500. Good shout there to all the other sites every one you mentioned.i watch very good tradesmen all know their stuff. Same as you very interesting.🤙💪😃

[@ronfrance4041]

Some missing variables to exactly figure out how much power was used to post heat the piece. But roughly the 150kva worth of units could draw around 900 amps maximum total, resulting in 249,000 watts, roughly $600US for 14 hour cycle. That’s at max load. Realistically probably half that was used since it was a gradual heat up and gradual cool down

[@jackking5567]

There can't be many companies with the abilities that your own has - it's specialised stuff and very impressive to see. The mention of a hot crusher from a days work: I blagged an opencast site visit and took my young son along. Staff fussed over him and made the day awesome for us. At one point, they stopped a huge face shovel for us so that I could get his photo taken stood in front of the bucket. The manager warned him not to touch the bucket as it would be hot from extracting rock for the dump trucks.

[@jackt9411]

In my engineering career I have often been presented with broken stuff to fix, in situations knowing that if I didn't do it, no one else would and just like you I had to get on with it. Although nothing even remotely approaching the size of the jobs you have taken on, well done. By the way, what's with the Trump poster? :-)

[@warrior4christ777]

Know what I'd have done?.... 🏃‍♂️ I'm a carpenter ; )

[@MarkMunro-y8f]

So It is true Leprechauns can make shoes and weld masssive steel machines😂😂😂❤. Uncle Drew does magic with his well drilling rig.❤

[@drewcagno]

Someone really needs to find you a camera operator. Just a thought, but might be cool to team with a local school to get some kids experience with the trades....

[@graemewhite5029]

Smashing job but the lads down the quarry missed an opportunity to Sharpie in a "crack" across the weld in time for your visit ! 😂

[@toolpusher333]

Love the vids I used to work for Press Construction and Babcock many years ago. This is how I remember workshops like these -- mangy LOL I did watch nearly all of the three videos but I have not worked out what that was that you were repairing. Remember the preheating used to do my head in. I was a fitter not welder but enjoyed that part of my life. I am 69 now but regards the repair not a lot changed really is there in last 30 odd years has there . Congrats on your 500 vids. EDIT Hell sorry I jumped in before the vid was finished must remember to watch ALL the vid to the end its a stone crusher 😄

[@raulrubio2862]

On Fire welding on KZbin is amazing please go support him he is awesome his name is Greg

[@Andrew_Fernie]

Must be a relief to see donkey sized rocks going through without a hitch

[@andrewjoyce7789]

Congratulations on the 500th. I don't think there would be more than a handful of engineering welders that could fix that piece in the world. Well done Alistair seeing that machine going again would have been wonderful.

[@Discovery123.]

You weld that with a Mig welder? Why not DualShield?

[@ShalomBrother]

Good to see you shouting out for welder fabber, it’s got the potential to be a massive channel.

[@CSWmanofsteel]

Just figured it out by hearing you say England?

[@KevinCoop1]

I was about to subscribe, then at 9:40 I decided, no can’t do it. Sorry.

[@handdancin]

why noy use some skateboard bearing instead of a brass bush?

[@commonsense7924]

Thanks guy. really liked the vids. I started in the NAVY as a welder retired then worked at PEARL HARBOR 28 years. Welding everything, even bicycle frames to submarine hulls. As you mentioned in one of your vids your elbows. I know what you are saying, knees, lower back ect. you know but the satisfaction I got from doing something that very few people on this earth can do was something. Now it really hurts so much that are trade and trades really is not passed on to young men or even women for the future. Just as Electricians, Plumbers, Machinists we are in a bad place. Thanks Again God Bless

[@mikecabral1579]

I’m 75 and was a pipe welder as a young man. I enjoy a day when I just had my head down burning wire (stick). The day went fast. I had to add more to my comment after seeing it run wow !! Great job a real craftsman.

[@davemitchell9941]

When I was working we’d have called you a genuine old boy. Over my years in heavy engineering I’ve worked among some wonderful old tradesmen & learnt a lot if they found you willing, as you obviously were Alastair. Nothing better than a willing apprentice in my book. Never made a mistake, never done a job. I use to ponder sometimes when a thing became ‘ beyond economic repair?’ BER. Never ceases to amaze me what can be done. ££££? An old boss gave me two pointers, lol. ‘ I want reasons why you can not reasons why you can’t & there are no problems only solutions!’ Always stood me in good stead when someone said; ‘ can you just?’ I’d love to see a cordless flux cored mig set up, that’d be something, lol. Made me chuckle! Imagine stick welding that with 7018’s & keeping the packets. lol. Keep up the good work, I don’t miss the grinding one bit, so fully appreciate your achievements. Thanks for reviving good memories as a fitter of my years in marine engineering & the ol steam work. Hard & heavy but satisfying.👍

[@peterwelsh392]

There are KZbin videos of welding prowess and methods & then 1 day looking through the run of the mill USA USA video's wondering why are there no UK welding video's EXCEPT you're video's go through out all manor of gouging oxygen propane gas cutting plus FCAW MIG possible TIG I might not have seen or MMA BUT THE MAIN THING IS YOU'RE CLOSER TO HOME 😊😊😊😊😊😊 TOP BANANA

[@allistairc123]

Thanks for support bud

[@nigelwright4796]

Wow just wow from a hobbyist welder this is just spectacular mate. Nigel Old Stoker retired RN

[@steve_weinrich]

I would describe your welding efforts on thuis project as superhuman. Amazing project!

[@honestjim1000]

is "1 donkey" an old imperial unit?😄

[@Lukie-pl7hx]

Very cool series but yeah that trump banner was a bummer to see

[@peterarmstrong8613]

Anyone watching this while not subscribed should be ashamed of them selves. Here, thanks to Alistair, we have witnessed very heavy machinery repair showing what it takes to keep the world turning. Who would know what it takes to execute this without Al bothering to set cameras and kindly explain the black art of his profession. Thank you Alister, that was epic.

[@conradward2945]

I reckon there's been a Few sleepless night's..Great video! ..including a lot of History..intregued to know how long the ware plates last on the crusher jaw's!..do they get hardfaced or just replaced..Hardox/Brunel 500? Cj Birmingham..

[@robertpeters9438]

I'd love to see that titanic eng in works video!

[@alangordon1677]

I'm guessing a video on machining some watch gears is out of the question!🤣

[@allistairc123]

Is that Alan Gordon crusher man?

[@seanohare8496]

Congratulations on 500 👍the first one that I watched was you welding a crain at the docks in the winter in the bad weather 👊 keep them coming cheers.

[@lovetools2685]

I don't usually comment, but this time it's an impressive piece of work. Congratulations! I am here for the welding.

[@yp77738yp77739]

What’s with the poster of Trump in the background? Reminds me of when teenage girls put a poster of the latest pop stars on their bedroom wall, but even worse as it seems almost homoerotic with a big gun on a tank. Something you might expect to see in a gay bar.

[@ACP-EFFU]

Pretty simple really... Trump saves America therefore Trump saves the World. Biden destroys America therefore Biden destroys the World. Like I said pretty simple....

[@ShEdward876]

Can't believe how well you speak Irish for an Irishman!

[@davidmelton7268]

Watched and enjoyed every minute of this series! Outstanding work! Thankful for the opportunity to watch your skill and determination in action.

[@larryperdue508]

Great job my friend 👏 in my younger days I worked for a company named Telsmith out of Milwaukee, WI, United States that manufactured rock crushers and supporting equipment portable and stationary ❤

[@dannycrooks8462]

There's rumours going about that you could weld the Titanic back together 😂

[@colbornfarms4849]

Not a rumor

[@MarkMunro-y8f]

I would never tell uncle Drew If I had a tooth ache😂😂😂❤ That drill owww.

[@nickarchibald2272]

What a really good series these three videos were, its great to see the quality of work and skill you lads have. Keep them coming.

[@Knight_of_NI]

Great job brother! I'm new here but ssubscribed after part 1 because your work is impeccable

[@allistairc123]

Thanks for support bud

[@MORPHEOUSUK1]

Not my usual watch on youtube but absolutely loved watching every minute !, quality work mate👍

[@k126kwx]

Congrats on the 500 mate. Just reading the comments is all you need to hear. Can’t say I’ve ever seen so much positivity for one man. You deserve it. Waiting for the next one👍

[@derekmartin2817]

Great to see someone that can repair things of that scale.

[@markfryer9880]

Alistair, congratulations on your 500th video and congratulations for beating the jaw crusher back together again! At @ the 9 minute mark I was watching the reel of mig wire go spinning around and around! 😊 I don't get to play with anything near your size of work but hey it is a school! 😂 Getting ready for driving the rental truck to carry the School Orchestra on a small two stop Bluestone Express country Victoria trip in early December. Wycheproof and Maryborough are the two stops this year. Last year was a much bigger tour, and there are some railfan videos of the trains in action on KZbin. Look up Bluestone Express. Merry Christmas in advance, if I don't get to chat again before then. Mark from Melbourne Australia

[@allistairc123]

Hey Mark good to see you in again! We are hoping to have friends from aus over Christmas! Hope you have a good one!

[@johnjelinek-g7b]

The most unbelievable welding feat I've ever seen . Thanks for this series . I was really skeptical at the start at how you were going to get this accomplished, but WOW, you did it in incredible fashion . A job like that will DEFINITELY test your metal, and make a way better man out of anyone . I bet in the welding part you lost a lot of weight ... I remember from crazy exertion jobs where I would lost ten pounds a day (but gain it right back again lol) so you must have lost fifteen . lol Anyway, great work to the whole team that had anything to do with it . :)

[@jayk5549]

Only in Ireland is a Donkey used as a unit of measure

[@allistairc123]

I was thinking sofa but it was more donkey size lol

[@Paul-pb3vq]

I would love to know how much electricity you used during the hole of this project, Don’t think I would want to pay the bill 😢

[@biomorphic]

Since the repair took so long, how did the mining continue to operate without that crusher? Did they close it down for a while or they have another one?

[@allistairc123]

They hired in outside contractor with mobile machine

[@biomorphic]

Impressive machine, and more impressive repair. There is a lot of knowledge that goes into something like that, I didn't even know it was possible.@@allistairc123

[@samwest9444]

Was replace ever an option with this part?

[@keltonwright7]

Few more questions. What wire and size did you end up using? Also what was the gas combo? Was that propane and oxy on that cutting torch to cut off those plates? Massive job and a great job well done. I wish i could get onto mig welding like you, Pretty decent stick welder but really struggle with the mig.

[@patwheeler9291]

You must have felt immense pride and satisfaction looking into that crusher working knowing the fantastic effort you put in! Awesome!

[@riflebird6433]

I don’t normally like or subscribe. You worked very very hard to get that done. I like your skill set and your patience. Good job man.

[@robseward7496]

Wow what a brilliant repair job bud simply amazing

[@gregquinn6827]

The Manlift shop here used to burn side plates and counterweights for boom lifts. I had to draw huge parts, full scale, on mylar for the tracer torch. The electric eye had removed the need to make aluminum tracer patterns. CadApple and AutoCAD didn’t come to me for another 5 years.

[@barrybirkey3282]

Nice Trump flag!

[@guywren4801]

Decision-making and work for grown-ups from clients to engineers all round. Many thanks for sharing.

[@fowletm1992]

Great work on the job, thanks for the shoutouts, few there iv not hears of, give me some solid extra entertainment

[@danielpullum1907]

I liked the use of the angle iron as a guide for the cutting. I cant believe I'd never seen that used. I see my Texas friend weighed in on your work also. He covers the south, I "cover" the Midwest in Illinois and our UTube friend Gregg "OnFireWelding"s got the west coast covered. You could spend quite a "holiday" just visiting us. I could get you a tour of the CAT Decatur Plant where the 797 "super" truck is fabed. Nine monster steel castings to form the frame. I do believe you welded the two left top blocks at least twice or ???? An amazing process. I watched another of a young man who built-"rebuilt" a jaw crusher a few months ago. I think it was for his personal property project.

[@SimonHarvey-i4z]

Not only was this a phenomenal repair that many would have walked away from ,he actually made it stronger and better than new at the same time ,pure genius WELL DONE M8 HATS OFF TO YOU 1st thing i have watched u repair on here im now subscribed and hooked!! Looking forward to your next project 😊

[@Professional-struggler]

Epic mate! Well done 👌 really interesting loved it! that machine eating them rocks at the end I thought it was going to struggle with the donkey but no! Some animal that

[@ronbuckner8179]

Your back must be toast.

[@willtricks9432]

You have this channel covering all the fun stuff. Cheers

[@joe2mercs]

You have been on journey from being “daunted” by something way outside your comfort zone the experience has given you greater confidence to tackle large projects. That which does not break you makes you stronger.

[@stuartlockwood9645]

Hi Alister, big round of applause for reaching 500 mark, and as for this massive project you've completed I'm in awe at your dedication to the job, superb workmanship, and well filmed at what must have been very stressful times . I've enjoyed every minute of the videos, and I thank you for making this possible for we viewers, look after yourself,best wishe's to you and your's, Stuart UK.

[@allistairc123]

Good to see you in again Stuart! Thanks for support as always

[@konstantinivanov1986]

Man I can't imagine how you felt but I was really happy to see that crusher at work at the end.

[@BrownCreature]

Suck a great edit mate. Brilliant fab work and video work. Your youtube work balance seems well fitting. Happy for you

[@PaulThomas-qo9vy]

Thanks for the "rick crusher" repair series! Amazing heavy, thick weldments, looks exhausting!