Forklift Axle Housing Repair

In this video I repair a worn out forklift axle housing that belongs to my good friend Joe from the welding shop. This piece of equipment is a vital part of his business and an important tool they rely on everyday, just like I do with my machines. So it was important that I helped him get it fixed asap, and that I did.
I decided to line bore the housing on the big Kearns boring mill at work, and do the rest of the machine work in my shop.
So in this video you'll see line boring, lathe work, and welding. I also share with you another shop made tool that I use.

[@bgdavenport]

I appreciate your minimalist style of commentary. Many of these YT videos bore one to death with useless commentary. You cut right to the chase and explain the techniques as needed.

[@timmayer8723]

Your narration leaves no doubt that you know precisely what procedure comes next, how you will accomplish the procedure and what past circumstances led to your process and eventually to a perfect part, IMPRESSIVE.

[@Uts9000]

as much as I enjoy watching the lathe work I miss the artistry of grinding a good working cutting tool. Most of us can't afford inserts. The advantage of inserts is almost invaluable to a working shop but please consider us poor guys, Watching your videos has always been informative, improving my metal work. Thanks again Adam

[@Abom79]

I grind tools pretty often, especially for grooving tools. I don't have all the inserts I need for every applications so I can make a high speed tool bit do what I want.

[@markmanwaring3823]

Your welding positioner has a cousin in my shed ,so bloody handy ,mine fits a 4 jaw as well and i made a foot treadle like an old sewing machine for hands free and a foot brake . I have fitted an variable speed hand drill to drive a belt slowly .

[@charlescompton4495]

A few years late but I noticed you seemed either under the weather or down for some reason. It's Feb. 27, 2018 as I write this and every time I watch you are all smiles now a days. Great work way back then, too! Greg

[@jeffryblackmon4846]

Your comments as you progress are very helpful. Your videos provide a lot of good material. Thanks. Jeff

[@jedtaylor3551]

Its the practical eye and the accuracy of it that intrigues me I'm a 2nd year wood turner and I tell people that nothing I do is on purpose I'm about good enough not to be dangerous Accuracy is a long way off along with a lot of skill Just love to watch this

[@boudreaumay3040]

I have no experience in this field but I do know it still makes me feel good seeing Americans being Americans and doing such wonderful work. Thank You for sharing and I'm sure your buddy will flip out and get back to his forklift !

[@Abom79]

Boudreau May Thank you!! The forklift has been running strong since the repairs were made.

[@boudreaumay3040]

There's No ! doubt in my Military Mind that it is.

[@morrisgray4761]

Your rotary welding jig was well worth the time to throw together. And the nice looking chrome sewing machine flywheel adds a bit of class to it. I disagree with the comments about adding a motor to it. Guiding by hand while laying down one of the smoothest arc welds I've ever seen couldn't be accomplished with a motor dictating the speed. Your videos are living history and should be preserved for when craftsmanship like yours has gone the way most such skills and have faded away. As a failed arc welder myself I think it would be great for you to put a welding glass in front of the camera sometime and show the world something most people have never seen and that is an arc weld actually being laid down. Keep up the great videos - thank you very much.

[@kurtarmbrust]

Watched this when it was first posted, then watched it again 6 years later. After seeing all your work over the years, I still get a thrill watching you take a rusty piece of steel and do magic to it.

[@arnodyck]

There's something very satisfying about watching those bushings getting hammered in.

[@joemehere1151]

My Dad was a mechanist his whole life. I used to pray for the days that he could take me to the shop once a year. He gradually became a tool and dye maker. Watching you work brings back fond memories. I can almost smell the cutting oil. Thanks again! I love your work, no matter what your working on. Since it was filmed in 2013, you'll probably never see this comment.

[@halliver3]

great detail and informative i have worked in workshops since i was 6 yrs old standing at a kerosene parts washer learning how things worked from the time i was 15 i was in the machine shop welding, milling boring , anything i could get my hands on i am self taught in a lot of things, but i am missing alot of things i really want to learn like thread turning, i watch alot of your posts abom79 and find your work to be the most informative and applicable to the novice , i am at the point now where alot of the stuff i learned from my dad and you i am using in my work on heavy plant equipment keep up the great work man

[@blueboy2589]

Brings back the memories, I worked in a machine shop for many years. Like a walk down memory lane. Mabie I should have recorded myself! Like to see a bit of gear cutting on the milling machine with a dividing head.

[@3melendr592]

Your techniques of setting up are like we learned them back in the mid 60's. At that time, we had machinists that had worked in the numerous factories for the war and peace time efforts. Many were of German descent as was my family. Two of my uncles were self taught and worked for TWA, Storekraft, Keyes and Dempsters to name a few. One of those two repaired watches and clocks. It would be an honour to work for a machinist like you!

[@fredjacobazzi3803]

I enjoyed your shows. My son is a machinist and like you he's very proud of his work..

[@rarejer]

Somehow I came across your videos. I am entirely un-mechanically inclined! I read books, write, bake bread. But I watch your videos, and am amazed at your skill, knowledge. Thanks!!!

[@Abom79]

+Jaroslav J. Peterka It's always great hearing from viewers like yourself. Always glad to know people who arent in my trade have interest watching and learning about machining and metal work. Thanks for the comments.

[@rrve9998]

You are very confident and serious on your job , that all I like about you , By the way I let you know my father is the excellent mechanician and owner machine shop .

[@bell9547]

Adam, you are a great machinist. That was nice restoration work you did on the forklift housing. Congratulations.

[@Patriot1776]

Adam, this video was especially educational for me, more in that it showed me how much work would really be involved in fixing up the bores for the ball joints on the knuckles for my STOCK Jeep TJ. The knuckle bores on one side got wallowed oversize to where the balljoints would not press-fit in anymore, they would instead only slip or fall in. My trusted mechanic welded in the replacement joints as a band-aid fix so I could still drive the vehicle, but highly advised AGAINST doing much, if any, off-road driving and that I would have to be gentle on the street with it, which I am doing until I afford the time and funds to get another axle housing. The method you showed here for repairing this forklift axle housing I believe would be the only surefire way to repair the ball-joint bores on my Jeep's front axle, and would just simply be WAY too much work when I could instead go and pull a good front axle out of a wrecked 90's Cherokee and it would be a direct bolt-in replacement for the most part. Still, this was very informing and educational, seeing all that would be involved were a similar job needed to be done on the front axle of a 4x4.

[@Abom79]

I feel ya man. In this case that axle housing would have been very expensive, and I was trying to help out a friend. Glad to hear the work was informative for you.

[@Patriot1776]

+Abom79 Just speculating here now, imagining how you might have line-bored the ball-joint bores on the housing knuckles were you asked to possibly to do such a job, like maybe for a fully custom front-axle build with non-stock knuckles and for some reason the ball-joint bores need to be sleeved. Non-Rubicon Jeep TJ's came with a Dana 30 front axle. The ring and pinion assembly would be on the driver-side, with the driver-side ball-joint housing bores the ones needing to be line bored in this case. I'm thinking the machined gasket surface for the diff cover would make a good surface to clamp flat onto the boring mill table or your parallel bars, IF the centerline of the knuckle bores are also parallel to that gasket surface. But if NOT, I'm guessing it would be time to work up a means to clamp it to the table by the axle tubes and rotate it until the bore centerline is lined up with the spindle. How good's my inferring?

[@g2macs]

It should be dull as dog doo watching this, but it just isn't. I didn't even do metal work at school but I find Adam, Keith and Tom more interesting than any T.V show. Thank's guys keep it coming.

[@gtbkts]

g2macs I agree.

[@softyzz69]

U should see This Old Tony, him and Abom are awesome to watch and learn from.

[@chrisberardi5999]

Great video. I'm an IT guy, staring at a screen all day. I would love to be able to do what you do. What an art - and science.

[@Murk_Lumpus]

Chris Berardi I suggest looking into CNC and G code, the IT field experience might help you out

[@jerkwagon]

haha me too, this work is fascinating!

[@woodiepritchett6885]

Murk Lumpkins m

[@tom5051666]

Nothing stopping you from learning to do this stuff. I am also an IT guy but I also machine, weld etc etc. I actually prefer it to dealing with computers all day. Good old non-digital hands on work.

[@michaelkreitz]

Same. IT guy who just bought his first lathe. Looking at that Monarch I think I went too small with a 1340

[@iancraig1951]

I am watching all your videos over again Adam and the way you hit your numbers when machining is very impressive because i know its hard to do consistently..Watching you creep up to your numbers and finish off with emery is a good idea..

[@kumiumiu]

the jobs you did with high skillful that i praise to you.

[@1rudymartin]

Man I don't think you know, how good you are .Please smile a bit .Regards .

[@moemaster1966]

Rudy Martin ? .. .

[@stephenpuryear]

your work smiles for you. Do what you gotta do!

[@nebtheweb8885]

@@stephenpuryear His newer videos he smiles quite a bit. He has become quite comfortable in front of the camera and on youtube videos. The video above is from 2013. A lot has changed during that time..

[@jlucasound]

@@nebtheweb8885 Oh, Ya! Adam made his life better and ours. Don't you love the stuff he does with Tony? LMAO.

[@Zt3v3]

When Adam smiles it usually looks like he's reminding himself to smile. I think he's a pretty serious dude.

[@kevinkirk4285]

Mundane repairs that no one thinks about and yet so vital to keep our country on the move. Excellent and fascinating.

[@richardcurtis556]

Adam; I am somewhat of a late comer to your channel. The difference in your self confidence and presentation of yourself is breath taking.

[@w056007568]

That's a great repair on a critical component - you appear to suggest that there is nothing much to it but that's not how I see it at all! To repair the casing in this way with the flange is inspirational as this of course is carrying most of the weight and get it all to come together correctly must be saving the owner a small fortune. As you say in these circumstances helping out your friend it's good to go the extra mile to help.

[@Abom79]

Thank you Dan. I just saved him a great deal of money by repairing this part, but it was a pleasure to help him out as hes always been there for me when I need help. The job is quite a challenge and I'd be lying if I said I had no worries during the machining process. it took a while to get that housing lined up and true with the spindle for boring. Also the reverse boring on the back side as I shown in the pictures is tricky too. You have to remember which was to rapid the table at the end of the cut so you dont destroy the part in the process! LOL

[@robertlewis4666]

I work on a 180 mini lathe, making small cannons, I love watching you work those massive pieces. Thanks from South Africa!

[@The52brandon]

LMAO "... another fun-filled day in the shop"? The joy and excitement while making that statement was overwhelming

[@abelewin2855]

It was a pleasure watching you doing a real professional work. There are not many people like you who do such rare repair work that involve welding and machining. I am impress with your improvisation for the welding fixture. I am looking forward to watch you again. You are a real professional.

[@KohalaIronWorksCase]

I'm a Shop Welder & a Field Welder, as well as a Shop & Field Mechanic I never envidioned being Pipe Welder, But that don't mean I don't weld pipe. You do amazing work!!!

[@robertw1871]

You’re a good friend, that stuff is probably better than it was when new.

[@LukasDubeda]

It's so refreshing seeing somebody working who knows what they're doing. So cool! And so rare these days...

[@HAL_9001]

Hey, I know it's almost 5 years ago, but you looked like you were going through some things here. You remind me of me just after I'd lost some good tools to an ex-wife who pawned them. Some of mine, my grandad's, and her step-dad's who I knew. It made me proud to see how well you dealt with whatever it was. Anyways, good job for keeping on going. Glad you look happier nowadays. And as always keep up the good work. Cheers!

[@davidfrench50]

love watching you work mate. I'M a textile engineer in Scotland who works with old old machines and I love the way you keep old machines going, i just repaired my industrial washing machine as the bearing were away and had worn the housing. I used some of you techinquies to repair it and its working great cheers.

[@Abom79]

+David French Great to hear David!

[@normandoty6133]

wow what steady hands, i'm impressed with how you started the welds, usually i get it stuck a few times before it starts to run. they are correct about running ground thru the bushings, you should probably ground at the hand wheel shaft to prevent the current going thru the bushings to the shaft but its not critical. i just love watching these video's they bring back so many memories of times long ago. keep up the great work, btw you are correct about calling some one to fix a light switch.

[@adamprice2299]

Hi Adam. Thanks for posting such informative videos, I'm 27 and i own my own small job shop in the UK, I am mainly self taught and i all ways learn something new from you're videos. I recently purchased a kearns boring mill, and i was wondering if at some point you could make a video showing the line boring bar that you used?

[@jonreiley5147]

keep on repairing America. that machine is lucky to have you repairing the parts!

[@darrellphelps9552]

It's amazing how much I enjoy watching someone do a fine job-

[@michaelrodriguez-fb8fr]

Hi Adam, it would be cool to get to see some more boring mill action, i found your thread on the practical machinist very interesting.

[@richardsensabaugh1312]

This is the first video I ever watched of his. I have been hooked ever since...

[@rickrasmussen5637]

I'm just a hobby guy and all these free lessons are awesome! I've learned so many great techniques from your videos. I can not thank you enough.

[@HanstheTraffer]

I learn more watching you in 1/2 hour than I learn on all the other machining videos put together. Thanks for sharing your skills. Common sense ...no BS.

[@GLN305]

Incredible work again. Dang nice of you to help a friend out, the world needs more of this!

[@paultarshipspeckerwood956]

Could you please do a video on headstock repair/ making lathe spindles run more precise. Thank you for all your time and effort producing videos that explain things, issues, and settup.

[@allancnc]

Always use left hand for deburring and 45 degree corners, or your shirt can get caught, we learn that in first class as a machineryworker or today "industrial technician"! (4.5 years) Be safe and keep up the good work. Allan and Noah

[@rickjennings608]

Great videos. You are very good on explaining and talking thru the steps. I am beginning home machinist for my car hobbies and am learning alot.

[@SGfabrication]

Really nice work.Thankyou for showing us your work .I did a ZF half axle repair ,only it was cast iron.I did what you did & line bored it .Made a top hat bush & welded it round .It worked out very well asp as that part is obselete.

[@gregg4164]

You may not be a pipe welder but you have one hell of a steady had and you weld damned good.

[@richardprimm5227]

this guy is a all around complete machinist .. to be able to think and plan for a job and then weld as good as he does and machine close tolerances. When is the last you seen someone use a h.s. tool bit ?

[@callez0r]

I don't do any metalwork myself, but still find welding and lathe-work extremely interesting. I really like your vids and your talent!

[@Twobeers1]

If I might be so bold to suggest. For your turning welding jig that you made, find yourself an old sewing machine. Strip out the motor & foot controller, adapt them to turn your jig. This will give you a stable turning speed & free up a hand.

[@MultiArrie]

handy tool you made, almost a welding manipulator for pipe welding. all you need is a windscheen wiper motor and a pwm circuitboard like a wire speed controler in a cheap mig welder.

[@bucksmith9035]

good job nice to see craftsmanship a trade thats becoming a thing of the past How lucky your friends/customers

[@gregdennis3523]

I love seeing the progression of the shop over the years.

[@larryhedeen5440]

The shaft you welded up is called a King Pin. That is used in a two peace system that is used in four wheel drive closed knuckle systems and in some two wheel systems. Thanks for the videos.--------Larry

[@localcrew]

I had one of those fancy welding turntables awhile back eBayd that thing and got like $800.00 for it. Course it had a variable speed foot pedal and tiny three jawed chucks and stuff. Your setup works great for next to no cost though so it’s the coolest tool for me.

[@melaniew77msn]

I just wanted to throw an idea your way. With a couple pulleys, a low rpm air motor and an air valve you can control with your foot that positioner could be magic! I know you can turn it by hand but machine turn is so easy and great for use with mig and tig work!

[@whitneybennett9045]

+melaniew77msn I thought it was a pulley, and that he was going to put a belt on it and slowly turn it somehow with some small motor system, and then much to my surprise, it's a handwheel! lolz ...but when I saw him use it I thought, oh how nice, hand wheel is definitely the way to go, simple and easy wins me over all the time.

[@1995jug]

Your are the MAN nice job, looks like you are burning the candle on both ends take care of yourself don't overdo it.

[@Buckrun11]

Cool to see people that know what they are doing working.

[@tamasmihaly1]

It's a privilege to be able to see you work, man. Nice job. A living legend.

[@allthegearnoidea6752]

I do a bit of lathe work for my hobby. The way you hit tolerance is amazing. Thanks

[@johnmorriss5308]

What a sense of power! Watching this video from 2013 in 2020, seeing that huge face-plate in the background of the welding table, and KNOWING what will happen to it in 2015! Rotary welding table!!

[@zatterberg]

Very good video, brings back memories of the days when I worked in the machine shops and on many of the types of machines shown here. That was over 60 years ago.

[@reideichner8597]

Nice job, Adam! Always good to help out a buddy. It comes back ten fold, and that is why you are friends. Thanks for the video. Like your welding positioner too. Reid

[@Abom79]

Thanks Reid!

[@tomoakhill8825]

An early video, and already excellent. Adam you are a natural talent at making videos.

[@douglasfurlong1]

I love your videos, they are great to watch and learn from and they inspire many people, and i just wanted to say thank you for taking the time to show people how to do things right. God bless you brother

[@SoulShak3nLIVE]

These videos are just so soothing to watch...

[@WisdomVendor1]

Dude, it cracks me up when you point at that massive chunk of iron with a hole through it and call it 'tubing' :) I guess it just shows the huge size of metal you are used to working with. Really enjoy your vids dude.

[@jlucasound]

You are so much better and happier, today. Wow, more than 5 years ago, this video. Day jobs will do that to you. You went "indie", and I watch your videos (I still have the "day" job); we are both happy! :-) Thanks, Adam.

[@lostpaintball7188]

I somehow came across your videos while browsing youtube. Now I am hooked. I do not know how to do anything you are doing but I am so impressed with the things you do. I have subscribed.

[@randytravis3998]

a buddy of mine had to rebuild his loader ,not the same model but just about the same repair , they welded in there repair where you pressed it in .. but his loaded is a lot bigger of a unit ,, great work you do .. i picked up a old lathe a south bend , 3 phase ,, need to get power to my unit transformer or other . learning a lot from watching your show keep up the great work ..Randy

[@WelLRoundeDSquarE]

Kearns horizontal boring mill. WOW I ran one in Ceres California that was built in England in 1929. (This was 1992) The one I ran hed a 10'x10' indexable table. I built a valve for City of New York Water Works where the flanges needed a record groove finish. If my memory serves me the biggest flange had a 60" bolt circle on it. I hand layed out the bolt circle, then dialed them all off using a center in the spindle. Then center drilled, pilot drill, and final drill. That one flange was 60 holes @ 15 min. each. 15 hours seems like a long time, but I was busting my ass. The one I ran had no increments on any of the dials. What great memories you stirred up.

[@Abom79]

That's a great story, thank you for sharing!!

[@WelLRoundeDSquarE]

+Abom79 Thank you for sharing your great videos.

[@hillearybrown7083]

+WelLRoundeDSquarE Great story! You mentioned a "Record groove finish" so is that exactly what it says? We had a Kearns Horizontal mill in shop class back in 69, Sadly the all of the Shop programs were deleted from all of the schools curriculum. Now days you call somebody to fix a dam light switch. Thanks for your comment

[@cityandsuburb]

That's incredible....!!

[@anthonyjackson4982]

The satisfaction you provide electricians like me ......Priceless.

[@tedrita2237]

Love that welding set up. I'm going to make one of those. Nice buildup.

[@bgdavenport]

Suggestion for your shaft welding setup. Acquire a variable speed, reversible DC motor that you can control with a foot pedal. You can get them for a song @ Surplus Center, along with the motor drive unit.

[@VinceCiotti]

You really do quality work! Both on the actual work and the video production. I love watching your videos.

[@johndonlan5956]

Another great video showcasing your fine machinist skills! Thanks for showing us the bit about the emery cloth..... I had no idea how you could fine tune a tight diameter that way. Adam, I think it would really be nice if you had some sort of a variable speed motor added to the hand wheel end on your rotational welding fixture. Perhaps an old sewing machine motor might work out. That way you could have the work piece slowly rotate at a uniform speed while you were applying the weld deposit. It may save you a lot of time and also make the weld deposit amount more uniform.

[@arth279]

10/10 on housekeeping & general cleanliness, & well maintained. Bravo.

[@george330ful]

Thanks for sharing the fact that you have the the fan running, I have 2 inches of snow to get to my grinding shop .plus 17 degrees Ohio !

[@Abom79]

Snow..whats that?? Hell i still have to get my grass cut! LOL! Yesterday was a little muggy, but the front moved through and it cooled off. I had my Dayton heater going this morning to get the nip out of the air.

[@keeganwebber]

Honestly, I think this is one of my favorite repairs you've done.

[@seantap1415]

I always, if possible ,do the bore first, more mass to help with chatter when boring.....cool vid.

[@tim47012]

Nice work! I like your approach to your jobs and I learn something each time I watch your videos. I know that fiddling with the camera for each and every job just cant be done but I appreciate anything you film. Thanks!!

[@Abom79]

Its a job in itself positioning the camera, turning it on and off, uploading, editing, and producing to the final product, but its quite rewarding when you have soo many people who enjoy watching you. Its fun too! Thanks Tim!

[@DrMerkwurdig]

Abom79 Well, I recently found that out... Trying to get something done is twice the challenge when you're also trying to film yourself doing it...

[@Abom79]

Your right about that Mattias Kristiansson. It takes longer but has its own reward by going the extra mile.

[@workwillfreeyou]

Thanks for your posts. I love the welding lathe. That wouldn't be too difficult to motorize. You could even have a center for it. I'm looking at buying or building one myself. Jim.

[@SalvatoreHP]

Beautiful work Adam that will last a long time instead of the cast, did a couple on a backhoe very challenging and rewarding im sure your buddy is very happy to have people like you around good friends scratching backs as they say... Ciao!

[@jasonrtaborsky4240]

Alright, we're about to check out Adam on 7018's. This is more exciting then the Superbowl!

[@frother]

A coma would be more exciting than the Superbowl

[@58browning40]

Adam, another job well done. You are a great asset to job shop machining!

[@AlphaFlight]

Shoot after a week of real job related welding, I find repair work kind of relaxing and fun.

[@mdouglaswray]

Great video! Good shots of the line boring! Love seeing these old machines being restored and allowed to keep working. I have to wonder how much commerce this forklift has aided over the years! Keep em rollin!

[@jpdemont]

Thank you for making and sharing these videos. It is a joy to watch a master. You give me hope that humanity is not lost. I think that is why so many people have a visceral reaction to your videos. By the way, your narration, photography, and editing are awesome.

[@Chevota22]

Great Job as usual Adam. I was surprised to see that after you welded that axle stub and turned it down that there was no porosity, inclusions, etc.... Very Nice! Thanks for the videos. Keep up the great work!

[@blablabla2530]

enjoy it a lott, always good to see the pride you have in making your work .

[@MichaelJohnson-vs3tt]

Gosh, I miss this kind of work. Great job!

[@hotquatur]

You could attach a simple hand crank to the face of your hand wheel to accommodate full rotation welding. Instead of having multiple starts and stops of the weld. Just a thought...

[@wdsracer]

Adam I like the repair videos best of all. All the techniques you use on repairs is very interesting. Thanks for all you do.

[@SynchroScore]

Nice green CR seal, I work in the lab that tests those. If you look at the new CR seals catalog from SKF, it even has a picture of me. And I don't mean to be making a plug for my company, but they also offer a product called the Speedi-Sleeve, which is a precision-ground component that can be pressed over a damaged or worn shaft, to provide a running surface for a shaft seal, without you having to polish or machine it yourself. I'm not quite sure of the condition of the part before this, but it could save you some time in the future, should you have a similar situation.

[@mrscrapper3331]

I’m definitely building a hand turn chuck! What an awesome idea!

[@jackmill4235]

I do enjoy watching your master pieces being created.

[@KingHelmer]

The smell in your workshop must be wonderful. :3

[@2bloodstone]

God bless you bro , your show is such a blessing to me love to see the work although I cant do it but it is fun to watch you solve the problems that come into your shop, keep up the good work.