SNS 157 Part 2: Failed Repair on Roll Journal

This is a recent job I had to tackle. It's a large roller for a local industrial facility, and one end of the roller has a damaged shaft. It was previously repaired by someone else and that repair failed.
I'll show you the failure and then proceed to fix it my way. We'll show some machining, tapping, and stick welding to get this roller fixed up and back to the customer.
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[@FrozenToast396]

I work for a small family owned machine shop. I run Cnc lathes including a really old Herbert 3m and a hardinge cobra 42. Man I have to say I have learned so much from you about tools and metal. I have suggested different inserts to my boss (also my uncle) and have had very good results. he has asked me where I have gotten this information from and I point to the shop Life T-shirt I often wear and say this guy right here. the other day I walked into the office and I caught him watching your videos. thank you so much for doing this. you have no Idea how much this helps people like me.

[@Abom79]

Haha! That’s good stuff! 👍🏻

[@SawyerArtOfficial]

Doriantool.com has some great inserts.

[@jafo766]

I ran a Herbert No 4 Senior Turrent Lathe @ Westinghouse , it was like being aboard a battleship , launched a aluminum casting from the soft jaws my 1st day , old $cotsman foreman told me " it's no Cape Canaveral lad " a nano second before cutter engaged I recalled not tightening chuck after truing casting...."you'll no do that again EH lad "....no sir....it was a long time ago in Canada.

[@GreeneAlien]

Awesome

[@sudhirpatole457]

Nice

[@StraightThread]

Your dad and granddad would be very proud of the high standard you maintain. Beautiful job!

[@tellmesomething2go]

Good roots.

[@elimalik2111]

Richard Freeze ‘

[@dfreezesr]

WOW do you know how rare it is to see someone with the same last name interesting in turning.

[@MikeSmith-lu2xe]

@@dfreezesr not really

[@MatthewHolevinski]

@@MikeSmith-lu2xe roflmao, funny I see it all the time.

[@jorluivil]

I don't work in a shop or have experience working with these types of tools/machines but I dig watching these videos

[@robertorr2878]

I am a cabinet maker/custom woodworker who knows nothing of welding or metal lathes but I like watching a craftsman who takes pride in his work. Hello from your newest subscriber!

[@bvcxzgt5451]

That part where you said, "Don't freak out." ... I was freaking out.

[@Godshole]

I have to take my hat off to your boss, probably for the second time, for letting you film at the office. It brings us real life working context of the life of a machinist and some great variation of applications. Three cheers for you Sir!

[@tcw8154]

Gustavo XD no this is his work place not his home shop

[@gdxd7956]

Oh, you're right. XD

[@niklaswallin9478]

win win win situation, we all win heh:-D

[@VB-bk1lh]

Filming this is good advertisement for that shop. Its probably the best advertisement they can get, plus it helps justify the cost of the repair.

[@Vandal_Savage]

'a little piece of emery...' great jumping jehosephat! - I damn near laughed my ass off when I saw that arm come in!

[@jerrydaugherty4657]

Yeah - that was my thought too! "Little Piece of Emery" = "2" wide belt - 36" long!" -- I'd hate to see a big piece of emery!

[@PsyMongazoid]

Judging by the comments here this guy is helping to improve the metal workmanship of the human race! Keep it up.

[@mojtababayest9491]

I'm an Iranian. I realy like the job that you do. I usually download the your videos and share it with my colleagues as youtube is proxied and a lot of people do not have access to it. I just want to thank your job and say, you are doing great bro.

[@bruces12]

Hello Mojtaba, I am glad to see someone from your country watching these videos. We, as Americans, would like to be friends with you guys and hold no animosity towards you and your people. Unfortunately, our governments have decided that we must be enemies, but that is not the regular peoples thinking. All we care about is our families and our livelihoods and are not concerned with trying to change your way of life. We understand as humans that we are all brothers and wish you well in you endevors just as we are sure you think the same way (do unto others as you would have done to you).

[@anotherguy1260]

Have you worked in any uranium enrichment facility's lately?

[@carrotbailey]

Mojtaba Bayest much love to Iran❤️.

[@ebutuoyebutouy]

@@bruces12 Thank u so much for making this bold statement. So true. Pray that the unenlightened get to see that ignorance is a loose-loose idea.

[@wallacegrommet9343]

Trump sucks. He has taken America hostage with the help of a frightened ignorant mass of delusional racists

[@lupuszzz]

So much skills, so much love and well explained to the audience - thank you very much! I'm not a machinist, but I watch all videos just because it is great to see somebody work at such a high quality level with such a passion.

[@buddynewman8949]

They don't make craftsmen like you much anymore. Great job.

[@knauregriffiths7666]

I love watching people who are good at their craft, whatever that craft might be. From your knowledge of the right kind of metal to use, getting the threads cut, getting a good, penetrating weld, and finishing up with a good polishing of all the surfaces demonstrates your dedication to your craft. Excellent job and thanks for the video.

[@larrysperling8801]

people with your skill set and problem solving abilities are hard to find. i hope your employer appreciates what he has in you. job well done. in another setting that job would have required a failure analysis followed by a written repair procedure and finally a weld xray. thanks for sharing.

[@paulhicks9399]

larry sperling I think Adam is the boss lol

[@Abom79]

larry sperling Thanks Larry. My bosses love having me around. They say that I live machine shop and they find that fascinating. We provide the customer whatever requirements they ask for. All of our rebuilds come with fully detailed reports. They can also receive a failure report once quoted if they request it.

[@Steve_Just_Steve]

Then after Abom fixes it they receive a success report at no extra charge=)

[@andrewnz8753]

Paul Hicks 🍃👤👃👤👨👤👨🥉🥉🚣🎽🖌📬🔑🗑🛴🚠🚠🚟😥👗👩‍👦‍👦👨‍👦‍👦👗🌼🌼🤷🏻‍♂️

[@qklmike]

Abom79 see. That's good work. Now when all there others break you will be the one fixing them

[@charlescompton4495]

That was great; I hope the customer appreciated the repair as much as we did, Greg.

[@johnw.peterson4311]

Adam, that was sweet man. In addition, good old stone reliable stick welding tried and true will hold where MIG will not cut it. Thank you. I have learned a great deal from your videos.

[@paralleler]

Thanks sir! Yep..., I started to freak at pipe wrench around 12:00. You knew what I was thinking and said, "It's okay, that's going to get machined off." You do such FANTASTIC work, thanks again! People with skill, what a novel concept!

[@patbrown2227]

Beautiful work. I like the way you talked through the cause of the failure and how you removed the bad penetration on the weld and the way you left a smooth radius between the end of the old shaft and your new shaft to remove the possibility of a stress concentration point. (Engineer with 35 years practice)

[@BruceBoschek]

Finally watched this and certainly was not disappointed. Excellent repair! Thanks for sharing it.

[@steverandall5814]

It's a pleasure to watch a creative craftsman work. Quality, durability, pride-in-workmanship, and "it's done right where is doesn't show"... these are the hallmarks of a master craftsman. Keep up the great work...America needs more people like you.

[@lilflatty2472]

I THINK ITS REALLY COOL THAT YOUR SHOP ALLOWS YOU TO FILM SOME OF THE WORK YOU DO SO THAT YOU CAN SHOW US THE DIFFERENT TECHNIQUE’S AND PROCESSES YOU GO THROUGH. REALLY ENJOY WATCHING.

[@illuminousanarky1047]

"just gonna use this air grinder right here" [GIANT BELT SANDER] gets me every time

[@geneelliott3230]

Abom, you made that look like childs play! Very nice job, thanks for showing us your expert work.

[@andrewjmcgee]

outstanding! as a retired paper machine reliability engineer, i do appreciate your excellent attention to detail! i also appreciate the paper maker's urgency!

[@FB-tq5ln]

Nothing but the best. It is a wonderful to see your skills. You have the best teachers. Not many can say three generation in the making of a tradition of skill you have. I am in the same league, my son is the forth generation in plumbing engineering. That SNOW engine is beautiful. From Dublin Ireland bless you all

[@adamlewis5144]

Best channel on KZbin. Pleasure to watch you work, Adam!

[@y0utubeu5ername]

Real nice job, looks fantastic - customer should be very happy!

[@robertoruiz7069]

I used to do stuff like that but on a lot smaller scale.You are a master at this trade.I sure hope that if any kids see your videos they might be inspired to become machinist.To me it's about doing something very few people are good at,that and learning the right way to do this job.Some shops that crappy would just say to the tech,just weld a stub on there and call it good.drilling tapping and single pointing that piece was a work of art .we need more like you THANK YOU for the video.

[@dimik3855]

Man, watching you work is a treat Adam. The filming and your commentary complement the job!

[@williamjc7195]

so happy you guys with real talent make these vids. thankx.

[@billdlv]

Looks like another solid repair, nice job Adam.

[@joevaagen6170]

I've watched a few of your videos and I find them very hypnotic, your demeanor, your explanation. Keep up the precision work.

[@bradleyb.williams1312]

WELL DONE !! The company has a trusted & knowledgeable machinist !!

[@Trumplican]

it is sooo satisfying watching a guy that knows what the hell he is doing!

[@erlingweiseth2774]

Love the way the threads fit on first attempt! Very high class work, Adam! ;)

[@ianmacpherson2409]

Hey I once worked on an old newspaper press. Apparently the previous owners had no spanners or anything more than several sizes of pipe wrenches. The sparing use of a pipe wench can be a job saver so no worries you have done a superb job on something that mere mortals would have run from. You continualy amaze me with your work. Cheers From Canada

[@bill8by5]

Watched several of your videos and am so impressed. A good friend and I were Engineers at NASA, and we used several techniques you use - but you've incorporated a lot we haven't thought of. Outstanding!!!!

[@nikkolaus]

i dont know shit about welding or lathe work, but this was entertaining to watch. Good job and thank you.

[@MaturePatriot]

Great work Adam. Looked better than factory, I would say. Hope Your recovery is going well. Keeping you in my prayers.

[@paltryengineer]

from one machinist to another you are an excellent tradesman. Really well done job

[@Damascus..]

nice fix. ive been a machinist, fabricator, welder my whole life and its refreshing to see someone take pride in their work like i do.

[@marcuscicero9587]

excellent thorough fix from a multi-talented man. hope the facility this roller ships to watches this vid. hope they're appreciative

[@johnfry9010]

Nice work Adam , that camera view was like having my reading glasses on , super clear , nice !

[@n0kjf]

I love watching people creatively make high-quality parts and repairs. Thanks for sharing.

[@LabRatJason]

Adam, your commitment to doing a good job regardless of whether the customer would know it or not is nothing short of amazing! Keep up the good work!

[@panther105]

One minute in and I'm subbed. So grateful to watch and learn from someone who REALLY KNOWS WHAT HE'S DOING..!!!! btw - I use pretty big Rigid pipe wrenches like yours at work loading and unloading tank cars with diesel. They take a beating and have never let us down.

[@Abom79]

Thanks for the sub, lots of videos for you to enjoy.

[@panther105]

I trained with a master aircraft mechanic in my dim, dark past and just watching his hands was an education. Same goes for you, sir...

[@edz7555]

Made it look easy and stress free...nice one Adam..👍👍

[@ddhts]

Great machinist, millwright and metal fab skills at work! Thanks for sharing, man!

[@Pete4875]

Your pride in your work shines through. Your a pleasure to watch.

[@jz9189]

Bad case of the "weeble wobbles." That's every monday morning for me 🤣

[@howder1951]

Nice repair Adam, I love it when you have to repair the repair, it has to be done right this time!. I think that crankshaft sander is my favorite tool of all time, cheers bro!

[@Abom79]

Gotta get one man! They are so nice!

[@leonmartinbroker]

@@Abom79 Where would a person pick up a sander like that? Thanks Leon

[@andrewterry8092]

Adam, your repairs always look better than the original. You are a true metal master!

[@johnsmith7709]

Adam, I have known guys who welded for 50 years who cant weld like you do. I am not a machinist, but I do enjoy your videos. I admire your reasoning, skill, and problem solving ability. Thanks for these incredibly informative videos. John

[@mikenixon9164]

Nice repair very professional!

[@Abom79]

Mike Nixon Thanks Mike!

[@kellerrobert80]

Yeah, his attention to detail on the 1/2" radius speaks volumes. Nice work.

[@Watchyn_Yarwood]

Beautiful repair!

[@pzro6869]

Excellent job Adam. Great video as always; keep 'em coming. Your Dad and Grand Dad would be proud

[@psient]

The pipe wrench is a marvel; spans the gamut of utility (no pun intended). In the end parts of your work, my shop life Tshirt came alive!!! Thnks to your bosses for endorsing your efforts on this channel, thank them for us please. I highly regard and am really thankful for these videos. A testimony to you and a reminder of your parents being responsive to what you could and did become. They and you shine in generosity, intelligence, and effort. You have made your daily narratives a blast to watch. It has been, and is, a pleasure following you from that first PM post years ago.

[@caahacky]

I hope someone at the customer's place cares enough to let you know how much they appreciate what a good job you did on this Adam.

[@Satelitko]

Title made me think you failed the repair. Good to see that wasn't the case.

[@billbibeau4747]

Luben Lambov 0

[@jamesmaida47]

I don't think he would have damaged the rubber, the far end was likely chucked on the roll journal on that end and the only time he was on the rubber on the near side was a little support from the bottom rollers on the big steady rest while the live center was also holding some of the weight.

[@blackdeath4eternity]

@Fester Blats it could also be out of a roller truck so who knows.

[@geovani60624]

@Martyn Watson you could try, but it would never get centered no matter how much you tried

[@carpenteire]

Fantastic video, great to see such quality work by a master of his craft.

[@77.88.]

Great to see a well trained machinist at work, total success story. THANKS !

[@patricksullivan9951]

Adam, another fine set of SNS's! OT can be your friend, and worst enemy... The entire 80's I spent 10 years doing 70 hrs a week, minimum! Made a lot of money, but burned out bad! Thankfully now I can refuse OT, if I want! Pace yourself, you are still young, and there are a lot of videos to make! Thanks for the journal fix, nicely done! Good tips there!!!

[@Abom79]

+Patrick Sullivan Yep, some guys love OT, but I love my personal shop time too.

[@Jacob-64]

Quality Adam .......😎

[@intrepid5592]

I really enjoy watching this Sir. Sort of hypnotic. And the critical, logical thinking used here is amazing...Tight tolerances in mind and machining...

[@ray6652]

Hello Abom.I am not an engineer.But you have got me glued to you tube watching you.And i find it so interesting ,The way you explain every step of the way.You are very talented engineer giving your time to others.*****

[@hotgta]

Perfect, as always. Thanks for the video.

[@jeffryblackmon4846]

100% in agreement! Great to watch and hear Adam talk about it as he works.

[@combatmedic1980]

Adam, just F.Y.I. when using a pipe wrench, the correct way is to have three points of contact, the two jaws and the back of the wench. It isn't a huge deal using it the way you did on a solid bar, but if you ever have to use it on a hollow or pipe, you can egg shape the pipe. Hope this helps in the future.

[@natedolman9443]

Matt Matt Haha been using pipe wrenches wrong for years. Never once thought to have it seated all the way back to keep it from egging pipes. Thanks for that!

[@natedolman9443]

Awesome video as always Adam

[@djmips]

Matt Matt i didn't know that exactly, but over time I found it just 'works better' to seat it all the way down. There's less chance to slip.

[@Bread996]

Good tip for thinwall stuff but definitely not the proper way for everything. Too much contact with the back of the neck reduces the clamping power of the jaws causing the wrench to slip. I use a chain wrench on thin wall stuff.

[@charles1379]

I beg to differ. Contact with the back of the pipe wrench will only reduce the clamping pressure if the jaws are not adjusted properly. Actually in an exaggerated case the further from the back contact point the less pressure can be applied due to the clamping action of the jaws.

[@deaftodd]

This dude really loves many different challenges. He's so confident!

[@karihardarson1234]

Makes my day knowing there are people like you out there Adam!

[@irench]

Excellent engineering and attention to detail. That repair will outlast the rubber on that roller.

[@benbilling4268]

Some time ago Adam said "I consider myself an average machinist" Well, if that was true, there wouldn't be too damn many real good ones out there. Impressive. Ben

[@stabilisedchaos]

As someone who used to work in an engineering factory, it is awesome to see a skilled craftsman at his job.

[@Machinist-wf1iw]

this dude does the perfect job and the perfect way of doing the job everytime you can not do a better job ..I love it

[@deej19142]

Hahaha I love it Adam. "That's all going to be turned, don't freak out on my now" Your commentary is second to none!

[@Abom79]

Ah you know the good ole pipe wrench is gonna stir up some folks

[@bjre.wa.8681]

Wonderful repair. You do work for a GOOD company, by letting you film while at work. They show confidence in their employees.

[@Raphael_NYC]

You are amazing. I am so grateful to you for sharing your thoughts as you work. Thank you.

[@markgrevatt4867]

Wow amazing job Adam the company you work for must be proud to have you.thanks for sharing your quality workmanship

[@robertroszell3972]

LOL Millwright Wrench . Good one Adam

[@howder1951]

You might as well sharpen the end and stab it right through my heart, almost a thumbs down from me, LOL! ( it's a pipe fitters wrench!)

[@jenniferwhite6089]

it was not a true millwright wrench it would be too much money for them to buy rigid tools they prefer harbor freight tools check like the Friday night girls the pickup

[@TheTurpin1234]

Damn those are some pretty good welds for a machinist.

[@Abom79]

I've been known to lay a bead or two down.

[@rmkscrambler]

The proof of a good weld was in the radius tool.

[@stuarth43]

some of us can do it all:))

[@keith73z28]

Adam, this is a Classic. I really know from experience that watching a pro, and listening to what he is telling you is very valuable to beginning your own journey towards excellence. Many years ago i looked at our Automated 600 ton Verson Mechanical Press and said to myself, "Wow i could never learn that". Then a few years later I was teaching that same skill. Watch and listen guys, and you will do well.

[@unicorn7337]

I'm always impressed by your work Adam, and learn a lot with each video I watch. This one in particular was fascinating... I wouldn't have known where to start with that repair and you made it look easy!

[@shawndinterman2219]

I may be a carpenter and dislike metal work but it's obvious the man has skills. The before hack job compared to the finished fix was amazing

[@blackhatter011]

Two carpenters were working on a house. The one who was nailing down siding would reach into his nail pouch, pull out a nail and either toss it over his shoulder or nail it in. The other, figuring this was worth looking into, asked, "Why are you throwing those nails away?" The first explained, "If I pull a nail out of my pouch and it's pointed toward me, I throw it away 'cause it's defective. If it's pointed toward the house, then I nail it in!" The second got completely upset and yelled, "You moron! The nails pointed toward you aren't defective! They're for the other side of the house!"

[@ChrisB257]

Masterful work Adam - my, that was close to steady rest! Heck of a job getting a good result from a large radius tool. That extended belt sander sure does the trick. Nice work. Have to say - that penetration on the old repair was awful!!

[@Abom79]

+ChrisB257 Yep, no penetration at all, just a surface weld.

[@samdavis5079]

ChrisB257 the"extended belt sander" is a crankshaft polisher

[@mareli82]

that "weld" was afull , more or less just a weld cap, time to start incorporating to QC on there repairs

[@pamancave1150]

Tore Nyland how could you tell the quality of the weld from just seeing 5 seconds of it ? And not being able to touch and feel or get a good look at it ?

[@gates2122]

Hugh G. Rection mig weld usually have not penetration. You can tell the weld broke from the parent metal.

[@advancednutritioninc908]

Adam - Absolutely Excellent Repair - Great Workmanship and Strength of final product!! Liked !!

[@jonminer9891]

Now I know why the world is going downhill. They aren't training guys like you anymore. You are the real deal. Thanks for sharing! Stay healthy!

[@turbocobra]

I am sure you will have some people "cringing" with you tightening that up, lol I always enjoy the repair videos

[@Abom79]

+Ramsey Customs - turbocobra Im sure, but that's why I asked them not to freak out on me... haha

[@peejay1981]

I love that you are'nt pedantic about doing things the "right" way - You just get the job done, and in a way anyone could be proud of.

[@Mrhollerr]

Why would people cringe? Are they scared of him stripping threads or something?

[@TheOriginalSycHolic]

not really cuz he flat out says its not the finished surface area nor the area where the shaft is actually used...

[@peterspencer6442]

Nice work :)

[@modelleg]

My grandfather worked a lathe his whole life. Thanks for posting.

[@tommybrown9034]

Top job... Really good to see someone with pride in their work. You guys are invaluable to all industries. Impressed. I would certainly bring jobs to you for repair.

[@robertkutz]

adam nice work.

[@onehandmedicgaming1925]

Coming from this old tony, his latest video introduced your channel lol

[@MarcoAntonioScevola]

Me too

[@thegibbonisreal]

@@MarcoAntonioScevola ToT brunged me here..

[@pyroman590]

Same here

[@peterchamberlain8327]

Me Too

[@FunkOsax]

You've done a fantastic job there, and so well thought through. Also much better cosmetically than they actually needed, but pride in your work is what it's about. My dad was a turner/machinist and I served my time as a fitter apprentice back in the mid/late 1960's (in England) and then left engineering to be a musician, but I will be forever grateful that it gave me an appreciation of problem solving and good skilled workmanship.

[@joseph73515]

I love seeing all these repairs , THANKS FOR SHARING ADAM

[@brandontrombley4978]

Abom79 can you make a short video of your belt sander you use to polish on your lathe? Thanks love you videos!

[@georgewocosky]

Hope the marks on the rubber don't cause any grief !

[@literoadie3502]

Was thinking the same. Wonder how he held it in the 4-jaw? Maybe some padding?

[@georgewocosky]

I believe the driven end is NOT 'fubar' as the end being repaired IS ! * Likely, he has the shaft padded to prevent jaw teeth impressions ! ( brass, aluminum, or copper ? ) Time will tell us 'the rest of the story' ;)

[@erlingweiseth2774]

Probably will be fixed with Tec7, if they do? Great stuff!

[@jamesmaida47]

I don't think he was chucked onto the rubber, it looked to me as if he was chucked up on the opposite roll journal on the far end and on the near end he just had the bottom two points of the big steady rest supporting the roller along with the center while he was trying to cut the radius.

[@antigen4]

the yes thats what ate through the rubber surface and grooved it ... the steady rest rollers

[@drewmog123456]

Mr Abom, you are THE MAN!! This repair is science meeting art in all their beauties.

[@katelikesrectangles]

Excellent job. I enjoy seeing what you decide to do, because it's really not obvious to me how to sort out that situation! Seeing why the previous fix failed is a good lesson too - in not judging their work, because I don't know the situation at the time that was done. Thank you as always.

[@coollasice4175]

4:51 _That's what I told the ol' lady just last night._

[@stevenkirkham3726]

Hi Adam. yet another top quality video. What was the tool you was using with the micrometer to check the thed ?

[@Abom79]

Steven Kirkham Those are my Grandads thread triangles. I have a chart with them that tells me what to add to my nominal size to get the proper pitch diameter.

[@blkcoupequattro]

Abom79 That was a good question, even better answer..

[@stevenkirkham3726]

Abom79 Thanks for answering Adam may be you could make a video on how to use them one day. Thanks again for your time.

[@steviegene4006]

Refreshing to see you take pride in your work. Well done!!!

[@animered1986]

I just wanted to say Abom It is really nice to see someone doing quality work these days that they can be proud of. Being disabled I am and constantly having to hire people to do work I can't do anymore. And it is very rare that I check someone's work and it is not half-assed done. and have to tell them they are not done yet. Seems like people these days just don't care about a job done well anymore.