Roll Journal Repair Part 1

In this video we'll begin the repairs needed on a larger roller. One of that shaft ends where the bearing sits has been worn down pretty bad. I show setting the lathe up including the steady rest, and welding the shaft.
next episode will be the machining.

[@lazaglider]

I've no background, or frankly deep interest in this subject, but there is something captivating about watching a master at work, regardless of his field. Watching someone make a job look so very simple, when the rest of us know we wouldn't have the first idea where to start. Thanks.

[@tamasmihaly1]

01:13 Freaked me out. Are you talking to me? Yes, I'm taking notes, sir. You are a real pro. What a work ethic. Love this channel so much. Never touched a lathe in my life, but what attention to detail. Thanks for teaching us a bit about this work.

[@Migueldeservantes]

That long belt sander was the most beautiful thing I ever seen! That is a hell of an Idea!!

[@Abom79]

Great tool to have!

[@ianbertenshaw4350]

Used a similar unit , we called it a bow sander or crankshaft linisher , i also used it to polish mono pump screws as it would roll around the the hills and valleys of the pump shaft - think of a mono pump shaft as say a 12 inch per turn pitch and a very rounded thread form like a sine wave .

[@justkiddin1980]

+Abom79 man this is by far the coolest youtube channel out there! thanks a lot for sharing your craftsmanship with us...i'm learning a whole heck of a lot....thanks again!! and keep em coming!!

[@Abom79]

+justkiddin1980 Wow...thank you!

[@timrees7274]

YES, but totally unsafe !!

[@tracylemme1375]

Can’t argue with success ,but over the years I have done virtually the same repair many times. First, I always machine the old surface to remove any contamination that may have been pushed into it. Second, I use a wire feed with .035 hard wire. I start at the very end building up the corner while it is still cool. If you then build up to the base, warpage is reduces greatly. It is best to continue welding until done. Be sure the end is built up enough.Let cool while still turning to enable even cooling. By following the tips the center will be off only a few thousandths. I will watch the othe episodes to see how it turns out. Thanks for sharing you knowledge and skills with the world. Craftsmen with your skills are getting harder to find all the time.

[@glamill51]

I know nothing about metal working - but this guy makes it compulsive watching!

[@littledad799]

have watched alot of your video's along with mr Pete's. really enjoy them. hope someone at your main job someone is watching and learning from you. you are a wealth of information. thanks for all I have picked up from you. just starting to learn about all this

[@Abom79]

All they want to know is that were making money. I share my videos to help many.

[@oxtoolco]

Hey Adam, Yes I was taking notes. I really liked the slo-mo when you were indicating the roll in. Tell Wes he should put a chain around that gas bottle leaning up against the other table. Talk to you soon buddy. Tom

[@Abom79]

+oxtoolco Always thinking of ya buddy! Talk to ya soon.

[@firetruckblack]

Hi Adam your videos are great. Your a good machinist. Working on the larger jobs is cool also. I was a machinist for 15 years in a hand tool factory. And I also use to live in Florida. Just stuck here in packer land good olll WI. We got no snow yet lollll. Well keep up the good work and thanks for the videos. I think I have watched almost all of them. Your cooking videos are cool to. Chris

[@lyntonr6188]

Excellent work Adam, I always learn something new from your videos.

[@victorfloresfernandez1589]

gracias por tus videos simplemente me han ayudado muchísimo en mi trabajo ,relativamente tengo poco que trabajo en maquinados industriales y gracias a ti y tus vídeos mi vida es mas fácil laboralmente hablando anteriormente solo trabajaba con plásticos haciendo fixturas para producción ,hoy en día trabajo en reparaciones de piezas metálicas .nunca pude ir a la escuela para aprender este oficio.pero siempre me las ingenie para hacer mi trabajo al principio tuve miedo y dudas pero aquí estoy .soy el encargado de un taller de reparaciones en una fabrica simplemente tu eres mi maestro cibernético aunque no hable tu idioma entiendo tus vídeos con solo ver de que se trata tu me Inspiras a seguir adelante muchas gracias señor a bomb

[@dalesimonds]

Nice job. I appreciate your effort at bringing the videos to all of us. Thank you!

[@Wheresmy240]

Thanks for the great videos Adam. You inspire me everyday to learn as much as possible about machining.

[@mikemiller7357]

Adam, You do some awesome work man. I also want to say that I really appreciate all the time and effort you've put into your videos, both in editing and content. Thanks and keep up the great work.

[@Abom79]

+Mike Miller Thanks Mike!

[@lorenlieder9789]

Good video Adam you get some neat projects to work on.Keep them coming.

[@WG1807]

Ha ha, I got that tip with the ground cable from Jody too, all the way across the Atlantic, here in England. Good work Sir, I like your videos very much.

[@jeffkreft9872]

I can't get enough of this pacemaker lathe, Love that machine! Hope to own one someday.

[@not2fast4u2c]

I like seeing the big stuff get welded and machined !!!

[@daque1960]

Size matters!

[@RichardHeadGaming]

+David Queen Thats what she said.

[@donaldmiller2154]

Albechtchuckpars

[@whitewa1e355]

I quite enjoy content like this. Maybe a few more videos like this, sprinkled throughout the regular uploads would be good

[@tolydukhovny682]

this must be a medium-to-light load roller from a conveyor -- judging by the comparative sizes of the roller and its bearing journal. very solid prep work and the 4-jaw dial-in! and i especially liked that jab to the ox-man. i'd give much to actually see your bead forming, brother adam. thank you for the video, -toly

[@StreuB1]

Thanks for the mid-week shot of a work job Adam! I have things like this happen to rollers on jobs that I design from time to time.......just a WHOLE LOT smaller!! LOL Have a good week man.

[@fortbrothers9809]

precision guy . every thing so easy for him coz he know what he do . abom #1

[@glennmiller9031]

I like the big stuff Abom . Very interesting. I like all your videos.

[@shawnmrfixitlee6478]

good job Adam , That should make a a good hard surface for the pillow block bearing !! Thumbs ..

[@swarfrat311]

Great video, Adam. I guess since you a big guy, you get the big jobs on a big lathe. Nice welding work! Thanks for sharing! Have a good one! Dave

[@Abom79]

+Swarf Rat Just part of my job, I've always seemed to get the bigger stuff, even from my old shop.

[@ChrisB257]

You have a steadier hand than I do Adam! Nice watching the vids on this huge type of work.

[@reideichner8597]

Nice Job, Adam. Looks like they took that cylinder out of service just in time. Not much left on the end you are welding up. Thanks for sharing. Take Care, Reid

[@Abom79]

Probably making some bad noises, glad they caught it.

[@cojns1627]

+Abom79 More likely that they caught it weeks ago, but waited till it got so bad they had no choice but to repair it. The way it usually works. Got to squeeze that extra nickel in before spending money on a repair.

[@DonDegidio]

Adam 7018 good all around welding rod. Used many of them when we needed to weld the rear housings of our dump trucks.

[@janvisser2223]

Hey Adam, Fun to watch as always.

[@larsmark]

Are you taking notes Tom? haha I love it

[@sdjb111]

Very Cool Adam. Man I weld every day all day. And after 25 years it SUCKS.... No don't really kids, It pays AWSOME.

[@robertkutz]

way to go adam tuesday after noon video you are the man. bob

[@travisshrewsbury7169]

great welding job as always

[@billdlv]

Nice job Adam. At first I thought that was a solid shaft and I though man those ends seem small for that size shaft. Then when it rang when you hit it with the chipping hammer, made more sense then.

[@Abom79]

+Bill De La Vega Yes those rolls are always made from a piece of tubing.

[@MrinsaneMr]

Oh and that powernater drilla sander thing was awesome!

[@0ADVISOR0]

Man, i cant get enough of this stuff! good work =) and know its time to go asleep.... zzZzZZzZ 11:07:07PM GMT+1 over here...

[@JustMeNoOther]

Good Mornign! Nice to watch another video =)

[@jarrettguthrie1670]

Strange, just subbed like a week ago, the place i work sells cast iron rolls to oil mills. That makes this video kinda neat.

[@nestortingzon3677]

Very nice set up and process procedure👍👏👏👏👏👏💯💯💯💯💯💯

[@1metiz]

"Are you taking notes Tom?" Buuuurn :)

[@anthonymason701]

well, he is The 4jaw King!

[@Peter_Riis_DK]

+1metiz Who TF is Tom?

[@anthonymason701]

+Peter Riis Tom is gus friend that challenged him to dialing in a part in a 4jaw. Adam dialed it in 1:16 and it took tom over 3 minutes

[@anthonymason701]

+Anthony Mason his friend* sorry, small phone and big fingers.

[@anthonymason701]

+Peter Riis if you look in Abom's videos, it is titled "4 jaw showdown"

[@DougHanchard]

Tom would need a stool and a long lever to turn the screws to indicate that sucker!!! :) LOL Poor guy. Nice to be able to rotate the part as you weld. *Jealous*

[@godzilla7382]

hey man that slack belt setup you used for the surface clean up. have you done a review of that tool? if not could you possibly do so? it looks like an interesting piece made from an older Milwaukee drill and spare parts that were laying around. good video man keep it up

[@JRD77VET]

Looking good. Suggestion- explain how you set up the steady rest for the folks who don't use them much. What seems "easy as pie" for you could be quite intimidating for somebody who hardly uses one. Jeff

[@lunardust201]

love that custom sanding tool!

[@talkvideo9059]

Nice trick using that cable around the drum for a circuit.

[@ilostmypie]

I'm studying chemistry right now, and i wish i had got into this. its the same sort of precision and knowledge of apparatus and processes but i just enjoy the idea of machining more.

[@Abom79]

Not too late to take some courses on machining.

[@thegardenofeatin5965]

@@Abom79 Don't know what corner of the world you're from, but having recently gone back to school and seen the state of the community colleges in my area, oh yes it is, by at least 40 years.

[@poulsejr1]

"Are you taking notes Tom?" Probably not... LOL

[@hugomartel8552]

nice ground setup mate!!! cheers!

[@timtrott4145]

Nice job as usual ,I assume the first setup was to preset the steady to facilitate re cutting the center .

[@daki222000]

why did you put it in the lathe the first time prior to welding, Adam? was it to have the tailstock center hole accurate before welding distortion for setting up the steady rest?

[@Moose_338]

+Flip de boer he probably cleaned it up a but for welding

[@michalrimmerak1646]

+Flip de boer I think, it was because of setting steady rest, because center hole can be after welding moved, when welded shaft bent.

[@EdgePrecision]

+Flip de boer I don't want to answer for Adam but this is the reason I would do it. When he welds the shaft it of course will distort and the original center will not run true so it will have to be recut. Lets say you didn't set up the steady rest before welding. You put the part in the lathe but how do you indicate the part to run true at the steady rest. You would need to run a indicator down the length of the part to check if it runs straight to the lathes axis but your carriage is on the right side of the steady rest so you cant without removing the steady. Basically there is no easy way to adjust the jaws of the steady rest on a long part without using some kind of center (you could have the part running off at a angle to the lathes axis). It can be done but it is a lot easer to do it while the center is running true. Than just remount the part and reindicate at the chuck and recut the center.

[@MrinsaneMr]

from a welder stand point and only seeing a few vids I'd say for weld prep, the base metal was ugly in the first clip and shiny clean in the welding bit.

[@Moose_338]

Could very well be he did both ideas suggested here

[@stoffes]

huge equipment , nice work

[@Edu_RJR]

If you want to try and record some welding footage with your camera, just use some zoom and manual exposure and put some dark plastic in front of the lens to protect it, maybe sun glasses will help, you can even try using auto exposure but make sure to use optical zoom only. Thanks for teh videos!

[@gnborba]

Nice job!....Waiting for the second part... :-)

[@MrJonny247]

Hi Adam from Sibiria! Cool dimension)))

[@craigleemehan]

Midweek content, whoo hoo!

[@jamespalmer3969]

i change out the bearings on those rolls while there in the machine, it was nice to see the setup and your process for the rebuild. I can't wait to see the rest. just by guessing from the corrosion on that roll is it couch roll?

[@castlerockmachine410]

Nice welding man. The way you made the vid, it looks like you chucked it up in the 4 jaw then pulled it and welded or is that just how you edited? That's a heck of nice shop you work in. Keep em coming man.

[@Ogma3bandcamp]

Voiceover audio sounds superb!

[@CompEdgeX2013]

OF course you know the viewership will want more like this right?? LOL Enjoyed this one. Just like being at work(only bigger).. :-) Colin

[@jusb1066]

+CompEdgeX soon we will be expecting new content everyday! lol such as is the problem of adding new videos outside the already busy regular content, the only thing i don't like about seeing 'part 1' on video is not knowing when part 2 is? do i stay up late or not have an afternoon nap in case it comes in?

[@Abom79]

+jusb1066 Ok I'll bite. It'll go live after SNS on Saturday. When I have some extra footage to share I try and space them out and post two days in a week.

[@johnbazaar8440]

+Abom79 don't listen to him. I need a daily fix, at least! Just kidding. 😊 Just do what you want. I'm happy with what I get. Lots of sparkling on that bearing journal. What was that, two hours? Nice work. Thanks, John

[@Abom79]

+CompEdgeX I try and get it when I can. When I see or know of a good job coming in the shop I bring the camera with me. Makes good footage to share.

[@CompEdgeX2013]

Abom79 I enjoy the shop stuff. Always nice to see how others do things, equipment, etc.

[@BuildSomthingCool]

Nice gloves :-)

[@Paddington60]

Hi Adam, is that hollow? It rang like it is hollow when you were chipping the flux off. Very interesting thank you.

[@tfp777]

I would have considered shrinking on a sleeve instead of welding it up, your comments Adam please, thanks for sharing.

[@danielwerger5641]

Hey Adam, how about a quick look at the "belt sander on a stick gizmo" you used around 3:20...! Shop made? I've seen it used in previous vid's and would like to know how it was made... Cheers, Daniel.

[@Abom79]

+Daniel Werger I'll add it to the sns mix one day.

[@danamurch8939]

First off, awesome channel and I've spent hours watching your videos. You are definitely a craftsman, I've always had an interest in mills/lathes and one day hope to have a garage full of tools such as you do. One question on the welding segment of this video though, maybe I'm wrong but it looks like you've got a bare copper cable looped over the end roll as your ground?

[@danamurch8939]

Edit: I finished watching the video lol. Stray-arc much with that setup? A lot better options out ther for placing a ground while roll welding. Might be worth a good Google.

[@patri0t1776]

Great videos @Abom79. Love watching the work you do. I was wondering, is 7018 wear resistant and how hard does it get? Can it be used for shafts with cast iron plain bearings? Or is that roller shaft set into roller bearings? Just wanted to know what the application was.

[@ramosel]

Adam, why did you do the stick weld as opposed to Spray Weld? Is it just the amount of build up needed? Again, not questioning your technique, just trying to learn. Smiled at your little reference to the venerable Mr. Lipton.

[@fortbrothers9809]

my like ur action . love that

[@richleviness4621]

nice work Adam! Do you problems cutting from the hardness of the weld?

[@kippostar]

That steadyrest overarm looks like the heaviest thing on the planet!

[@jusb1066]

+kippostar .kippostar i think the huge lump of steel he is turning might be heavier!

[@anthonymason701]

+jusb1066 that roller is hollow. the shop where i work recoats the roller journal and grinds them back to spec.

[@jusb1066]

Anthony Mason i didnt think of that! lol

[@anthonymason701]

+jusb1066 dont get me wrong, they are still heavy as hell, but not as heavy as you would think lookin at it

[@DL5FS]

Nice one!! is it possible to show us your Workpartners or your Boss in a Video ?? thank you

[@Bondolomata]

Hi, how about to weld an sleeved bushing on each extreme to avoid bending and basically the whole welding. One thousand press & thread locker.

[@ScottandTera]

hey adom just curious why not use the metal spray like you did at your shop , also would not a mig welder worked just as good and would have been continious from start to finish?? trying to learn

[@jefftaylor4821]

Dumb question. Could you have turned the bearing journal down and then put a harder steel sleeve over it?

[@619Lloydzrox619]

Wouldn't a larger journal make more sense for a roller that big? Not enough surface area for my liking. Nice job Adam.

[@GUSMIX22]

Adam absolutely awesome.. Love the ground strap, and one of these days I need to build a turntable, although certainly not that big... :) Was wondering why not flame spray ? maybe too much needed to build up etc. ?

[@Abom79]

Way too much wear for metal spray.

[@GUSMIX22]

+Abom79 Thats what I thought

[@chetvaldes]

Adam, the quality of your camera work, and video/audio editing just keep getting more and more professional looking- do you have a pro that advises you or are you just figuring it out as you go? You're making some of the best machining videos I've ever seen.

[@Abom79]

Im all self taught. I pick the shots I want and blend them together. All I use is my GoPro and rode mic. Thanks for the comments!!

[@brothyr]

Did you make that huge belt sander yourself? Have a video on it?

[@circletree]

+Adam R it is called a dynabrade

[@HomesACT]

Hi Adam what are those bolts that you where tightening on the steady rest while you where adjusting it? are they just bolts to stop it moving once you're happy with the setup

[@The313william]

You look like a great machinist man. How many years of experience do you have? I'm currently 19 and already have 2 years in machinery thanks to my grandfather.

[@Abom79]

+The313william That is awesome! I started when I was 17 also! Now I have 18 1/2 years under my belt. Started in 1997 with my dad at our machine shop. My Granddad also taught me and was a huge mentor growing up.

[@rickpackham]

I just started doing this job.. do you have any tips on avoiding pin holes and porosity. I used a mig welder though.

[@freethought2296]

Why did you dial it in on the lathe before you welded it? Your welding is excellent by the way!

[@Abom79]

To preset the steady rest.

[@MrinsaneMr]

:-O that ground cable trick was impressive. A mig machine might have saved you some time, but your stick welding isn't too shabby.

[@Abom79]

+Mr Mr That mig welder is the birds. It's got it's place for me though. I like the performance of stick for most of my work.

[@MrinsaneMr]

+Abom79 I agree I'd stick and tig any day of the week over mig, but I used a millermatic 350p on this one job and it was pretty good... for a mig.

[@dougbourdo2589]

Man, I tell you what... if I lived anywhere in Florida, I'd want to know what shop you do this work at so I knew where to go for serious metal repair.

[@AT.retifica]

I have a universal cylindrical grinding that takes up to 1500mm between centers.

[@richardhead8264]

Really enjoyed that Adam. Just curious, does your employer get "wound around the axle" with time studies, efficiency and bean counting? Or do they simply trust you to do the job? Thanks!

[@Abom79]

My boss does all kinds of studies but it's because he enjoys to. We do have to be competitive with our prices though.

[@arnomaas6452]

you mentioned jodie about the copper ground trick .. was it jodie from weldingtipsandtricks ?

[@EJConrad]

Sweet ground!

[@TheBackyardMachineShop]

nice work Adam, I am jelous of some of the big work you do. I don't get to see much of it in the aerospace side of the trade

[@Abom79]

I do enjoy the big projects and big lathe work.

[@BeltraKTM]

Hello, why you choose to use stick instead of MIG? Thanks, Andrea

[@MatthewTinker-au-pont-blanc]

What rods are you using? You just said it on the video 7018 thanks!! Thanks Matt

[@Abom79]

+Matthew Tinker Yep, 5/32" dia.

[@Gkuljian]

I saw the ground wire, and my first thought was Jody. We're all learning from each other here.

[@ShuffleSk8Ter]

Walkin Dead helmet eh? NICE!

[@jusb1066]

+Lawrence Harasim someones gotta be able to weld when everyone has turned into zombies (oops have to call them walkers)

[@masterahlstrand]

Love your vids..........

[@deepwaterescue4u]

keep you a bucket close by to drop the used rods in saves on clean up time

[@sharpx777]

Adam, cool vid, thanks for sharing. Asking this for my own benefit - what was the reason you chose to build it with weld rather than cutting and welding another stub shaft (looks like there was a weld bead on that stub). Was it pressed in and then welded? Could you have drilled/bore out the old one as an alternative? (to understand the choice from my hobby level and not anything else)

[@joshua43214]

+sharp x I had the same thought until I realized the roller is a hollow tube. You would have to remove the end cap to weld on the back side of the shaft. Simpler and faster to build up the journal with less risk of distortion from welding the end cap back on.

[@sharpx777]

+joshua43214 good point, to me it looked like the weld was on the outside but you're probably right and there's one on the other side as well.

[@mayhem7090]

Hello Adam, good job reloading, what is the maximum weight admitted by your engine welding drive, you have made a distemper after welding, really cool setup, cordially thierry.

[@Abom79]

If I remember correctly they can handle up to 1,500 lbs.

[@mayhem7090]

Adam thank you for your answer, good luck to you and continue to impress us with your superb always interesting video.

[@kolkatarchadbagan1090]

Sir ,when will i use steady rest? Can i use when we facing vibration on the job due to machining large job ?reply sir..i'm learning lathe work...

[@anthonybalducci8134]

out of curiousity, How come you arc weld that instead of mig weld?

[@richardwesterfield4578]

where did you or your company get the sanderthank you Richard wesrtfield

[@mertsilliker1682]

Adam what kind of heat temp were you using on welding this unit. nice as usual

[@Abom79]

+Mert Silliker As far as welding goes, 160 amps

[@ianmyers1593]

Why stick weld?...wouldn't mig welding lay down more material faster?