The Craziest Weld Repair I've Ever Done

[@subliutenant]

As a retired Coded welder with over 50 years experience in MMA, Mig, Tig and Oxy / Acetylene, this is a good repair! Nice to see a craftsman willing to pass on his knowledge! Good man and Bollocks to the Thumbs downers!!

[@sailjunky7326]

I agree. I did this king of repairs for many years on a daily basis. I learned the basics from my father, and built on that. I always had the impression that anybody could do it. But the truth is, it takes talent, skills, knowledge, practice experience and the right equipment. The hardest puzzle I had to do, was probably to put back together a brand new magnesium chainsaw casing after it got run over by a tractor. That got my skills stretched to the limit to get all the parts to fit right and true. But I saved the machine and the customer was very happy.

[@subliutenant]

@@sailjunky7326 Yep, My Dad taught me too! He served his apprenticeship with Swan, Hunter, Wigham and Richardson on the river Tyne. You have to have a 'can do' attitude and always be hungry for knowledge also being unafraid to venture into the unknown! Don't be afraid to experiment and don't be afraid of failure! Learn by your and other peoples mistakes.

[@petehorsburgh4584]

Sweet Triton Mo!

[@subliutenant]

@@petehorsburgh4584 It was a Dominator 88 with a 1957, 498cc Doug Hele 90 bore Manx Norton engine, road registered and I rode it on the road.

[@firstmkb]

No idea why someone would thumbs down!

[@GrantSR]

THANK YOU for actually explaining what you are doing! I'm so sick of 99% of KZbin channels that basically just show of that THEY know how to do something without actually explaining anything. Or worse, never saying a single word.

[@koitorob]

I'm surprised you used the method you did. I would have guessed you had cut off the damaged section leaving space to weld without affecting the mating face and welded on a length of tube of matching diameter and thickness. The end result, especially considering the method, is outstanding!

[@travisabrahamson5092]

Ever since seeing my dad re make a sprocket for my dirt bike when I was 9, I have been amazed at what ppl can build / fix . I now will attempt anything with metal. Welding/ fabricating is so satisfying.

[@ofbaran]

I'm not even into metal works, I'm a computer engineering student, I don't know how did these videos got recommended to me but I got hooked up on this, it is amazing watch welding, you just earned a subscriber, sir!

[@RickaramaTrama-lc1ys]

So you're NOT one of the shops that says"You can't fix this~you will have to order a new one"~! I knew a guy like you in my youth and you really remind me of him and he was also a Natural=Just like you. Great video and put me down for a subscription. Thanks.

[@dant1983]

I honestly didn't know this was possible. Makes me want to get into TIG welding.

[@kyleglenn2434]

You should. Tig welding takes a day to learn, a lifetime to master.

[@josh5318]

At my old job I had to do this kind of repair all the time. It was a pain in the ass because the robots would always burn through this tiny 1mm tube with a 90 degree bend on it. Repairing that thin of metal is difficult enough but adding that annoying bend was the worst.

[@jonathangarzon2798]

@@kyleglenn2434 I've yet to see anyone learn tig in a day, mig I've seen people pick up in 30min, tig not so much

[@proxypanda4156]

@@jonathangarzon2798 I did in 2 days with previous welding experience.

[@calebr9736]

@@proxypanda4156 I'm sure with some welding theory you can get any process down in at MAX 3 days

[@jensonhartmann3630]

It's also that quick with the hands of a skilled welder. Knowledge and knowing how to be patient are key.

[@tylerangle1990]

Man you killed it on this repair. Not only to be able to do it well but also do it that quickly is a real testament to your skill.

[@YT-User1013]

Wow, so cool to see how a pro would go about repairing something! I didn’t think you could do a “fill” on this, but now I know. Thanks Justin.

[@pyro323]

Wow, if I never saw this video and saw the repaired part I would've thought the customer replaced it. Nice job fella!

[@wolfsProjectFiles]

Nice repair! I never would have thought replacing that missing chunk with weld would have been viable.

[@cuteface88]

Of course it is. That's repair welding. lol

[@wolfsProjectFiles]

@@cuteface88 I would have tried to weld in a chunk of tubing.

[@richardschofield2201]

@@cuteface88 don't be that guy

[@cuteface88]

@@richardschofield2201 No problem, Dick.

[@MelbaOzzie]

Very nice work. It's always a joy to watch a craftsman at work.

[@joeclarke9782]

Thanks for getting right to the problem with no extra unnecessary blab. Good work.

[@farmalltomf]

Justin, outstanding walk-through on an "OMG" repair. Great delivery on thought process, technique, and execution. My mentor taught me 40 years ago, "the mindset for repair, and the mindset for build new are different". This was an outstanding repair delivery. Well played my friend.

[@davidyisrael007]

You must have had a hack for a mentor. This guy is extremely dangerous. Anyone who has spent any real time in the shop would run from people like this. He would never ever work in my shop. And neither would you.

[@davidgould5708]

Unreal speed and precision with minimal help from tools. Awesome job

[@davidhenderson4883]

As a retired aircraft welder ex RAN Fleet Air Arm that is a great job IMO. Well done!!

[@MacDaddyTito]

Teaching myself how to tig weld and plasma torch right now. Saw this and now I know how to repair that corner of the tranny oil pan! Thank you!!!

[@russellstephan6844]

It's always amazed me the results which can be obtained from basic hand tools like files and die grinders when one takes their time. Nice repair!

[@Ropetangler]

If you like good work with basic tools check out Alan Millyard

[@Fridelain]

Khyber pass is a testament to that

[@stevenmitchell6347]

Excellent repair and very educational for the inexperienced. Explanation of the process and reasoning behind it is one of the many reasons I continue to follow you. Well done!

[@tomthumb3085]

Nice to see someone actually doing stuff instead of telling us all about their viewer gifts or comments. Great video, thanks

[@coryduke69]

That's pretty cool, I'm a below beginner booger stick welder.....love that yall put out these videos

[@michaelalmeida8790]

End job looked good and another happy customer, I'm sure. Next time you get one of these projects try using a sleeve/coller to wrap the outside and weld the inside first. Then you can pull the coller, grind down some of the junk from the backing and run stringers all the way across the face from the base to the edge. I use this technique when I'm trying to maximize weld quality and minimize a "dirty" weld. It allows you to run lower amps as well. You might like it, you might not, but figured I would share because you're skilled enough to pull it off. It's more work, but it gives me a higher quality weld.

[@mosesmanaka8109]

Very well spoken for the general perception of a welder.

[@sly2392]

one word. TALENTED.

[@jmy7622]

I remember using that method a few times but not on a round machined part nice work! People think it's easy, but to repair something like that and sand it to look machined isn't easy.I've fixed steel too, as a backer I had some brass.

[@wolmntn]

I love jobs like those. I did a few Harley crankcase and covers. I did a head for a Harley. After it was resurfaced worked perfect. I like watching a welder that know what he is doing great job.

[@Jbmc65]

Excellent work buddy. Omg that turned out excellent. I would never have thought about the stainless sleeve inside. Saved a huge headache grinding.

[@eCitizen1]

Thanks for showing us this. It's a great technique to salvage something impossible to find parts for.

[@robertoacevedo3805]

Dude, I repair boat parts all the time exactly like this. This is a very impressive repair. Right on.

[@Ichibuns]

Most fabricators would either say no to the job or still be thinking about it after 1.5 hours. Top notch work. This KZbin channel is better than any resumé

[@billbudnic2941]

nice job. did a ton of this kind of work for many years. watching this really brought back memories. thanks for sharing.

[@kevinw3030]

Your skills remind me of an old Sunday School teacher of mine. He worked in the prototype shop for a defense contractor. Basically if it was rocket powered, it was built there. From Stinger missiles to Poseidon missiles, Tommy had worked to make them a reality.

[@sweetlord5099]

Tommy who?

[@randr10]

That would've taken me three days and it probably would not have turned out as well. Nice hand work.

[@tomtech4224]

It's interesting to read all the comments about different ways to fix this. I live about 15 to 20 min away from his shop. Most of the places I go for parts, materials, and tools I can't get on line are about 5 min drive from his shop. Almost anything you can imagine for this repair is available less that a 30 min drive from his shop. I watched and would have done the repair very different given my tools and experience. I would also have done it very different if I had a bigger mill or the ability to tig aluminum. Given all that, you would spend more time driving and waiting in line than he did with a tig and grinder. How much time standing in line is billable? If it had been a pinion hole in a diff then his hand finish would not work. However the welding to build up is about the best option. It's an exhaust part. Close enough is good enough! Fix it, bill it, move on! Unless it's a hobby.

[@bigdfitness5020]

So say he drives 25 minutes there, spends 10-15 minutes buying what he needs, then drives 25 minutes back, that is already an hour and 5 minutes. Now after all that he still has to fix the part, and by the time he sets up to get started on the repair he is already done using the method he used. Plus no wear and tear on the vehicle and no money spent out of pocket.

[@kentdixon5716]

Awesome repair, loved the process of repairing something that almost looked unrepairable , well done thanks for posting!!

[@martinjohnson9316]

Enjoyed watching a craftsman at work and very well presented video...thank you for downloading!

[@runvs7470]

Do it all the time. It's fun bringing stuff back to life.

[@BigLouWelds]

1.5 hours wow! Looks great! Nice detail in the video also with the describing what you where doing and why. Thanks for the video

[@calebrogers9977]

Wow. That was really awesome to see as a student wanting to get into the weld repair industry. Thanks for showing us. I really liked the content and would love to see more like this.

[@theshepardthewolfandtheshe5304]

Right on! That wire wheel thing on the grinder is a lot faster than my rigged up wire brush on reciprocating saw.

[@killerdude4317]

You are awesome 👍🏻 i just bought my fist tig machine and your videos really helpt me start up.

[@raydreamer7566]

I love tig welding and I can really appreciate your work. I am in the Philippines now and I do not have a Tig welder yet but I brought my Henrob Oxy Acet torch with me it does cover all of the bases just sometimes not a pretty . My consumables are motorcycle spokes carbon and stainless and piston rings from big diesels motors for cast iron welding and I will cut into strips aluminum motor bike covers when needed for welding aluminum. I use what I can find here these are my welding rods. I really enjoy watching your videos......

[@gradyrm237]

That's incredible. Nice work my friend. You're an artist.

[@bighandproductions55]

What a well-done, informative piece. Your voice-over was concise, informative, and did not meander. I really enjoyed it!

[@craigpierre2765]

awesome work and 1.5 hours on a job like that is well worth it for a part you cannot find cheap. I'm sure the customer was happy.

[@dreoneful]

Attention to detail is always appreciated personally when I see this type of work I always go back regarding price

[@polloloci21]

Damn!!! 1.5 hrs. You are quite skilled

[@gurjindersingh199]

You are one of the best welder/ fabricator I have ever seen.

[@thornyturtleranch4u]

I rebuilt an aluminum Mercedes engine part once for a friend. Worked perfect. It was some kind of engine from cover. And I did something like this on a turbo intake part. Thing is it was like my 5 or 6th times welding. Minimal experience. Turned out good. Now I have to get back into some welding. I miss it.

[@FantaBH]

well done bro. Nice to see craftsmen willing to do a job like this.

[@Natural-Causes]

No idea why this was in my feed but I love this stuff and you now have a new follower, nicely done....👍

[@johnnygoins7457]

Nice work.i didn't know you could weld on steel and not stick very informative.

[@thebubbacontinuum2645]

I like your videos better than the ones from the other welding channels. Seeing how you get actual jobs done is more interesting than, "This is how to do a butt weld. This is how you do a lap weld." Your video demonstrates one of the best things about welding. You can put metal back. It's not just about fitting two perfect pieces of metal together and joining them with a bead. I wish people would do more videos on straightening. I had to figure out that TIG straightening existed, all by myself. You should get more angle grinders.

[@TheEquineFencer]

I learned something from this, that's a good way to start my day. Know that the AL would not stick to the steel is good....knowing what will happen if you pull and arc to the steel is good to know also.

[@colinmccauley3301]

this is true craftsmanship in action. good job.

[@audikid89]

To fit that on the lathe attach the exhaust tip to the compound slide and put a boring head in the chuck

[@CJ-ty8sv]

Yep! Or if you have a turret head type bridgeport (or clone), you can also bore it on the mill by running the table all the way back and side clamping it vertically off the face of the table (most have a T-Slot on the face for doing things like this) and then rotate the turret and move the ram as needed to align the quill really close with the bore, use the X and Y to make final fine adjustments and bore it with a boring head. I do this quite often when I have to bore pipes that will not fit through the spindle of my lathe. Basically the floor to tip of boring bar tool used becomes your part length limit. You can also use large v-blocks and other fixtures on the table to mount parts hanging off the side too.. The possibility of mounting are numerous.

[@Motodents]

@@CJ-ty8sv thank you for this, i never thought of doing that. and now hopefully ill remember it when i need it

[@CJ-ty8sv]

@@Motodents No Problem!!! Hope it helps. On the subject, it surprises me how many people I've talked to / mentioned that method to over the years that have never thought of or heard of using a mill like that despite that being one of the reasons why Bridgeport put the Turret and ram feature on many of their mills. Also, If the part is small enough in the X and Y directions, as long as its clamped well, you can mill features too by just using the X and Y feeds like normal.

[@jrfoleyjr]

I love watching a craftsman/fabricator at work. Great Job. I don't understand them but there are always haters out there.

[@BillWood1]

Great welding skill and interesting technique. I've used a similar technique on large, commercial water tanks. However, just out of curiosity, why wouldn't you just cut the flange all the way off and replace it with a piece of tubing? Even if the tubing had to be machined to the right ID and OD, that strikes me as being easier, more consistent, and better final result.

[@Fridelain]

And he could just make the tubing by bending a flat piece cut to size and welding the seam.

[@Random-bm7ho]

Being this is an exhaust I would have removed the broken tube, counter sunk, and welded a matching tube on rather than repairing it. If that flange could come off weld both inner and outer surfaces, machine smooth. I would be concerned with the weld cracking over time, with it being the exhaust

[@costaliberta5969]

great comments

[@Tagerrun]

First time seeing his videos. I’m assuming it’s the fastest method he has available to him. Maybe not in a big machine shop with a lot of tools/machines to use.

[@BillWood1]

@@Tagerrun I'm sure you are right about not being a big machine shop. You could still use a piece of tubing since exhaust tubing is a fairly standard size and then weld that. As for machining, you could also outsource that as well. Turning down a bit of aluminum shouldn't be too costly, but, I don't know that for sure.

[@smportis]

Really good for all manual machining. Appreciate the work.

[@eugenedavis2328]

Most insane pieces I welded were when in Votech Welding in HS. I'd pretty concentrated on TIG. One day, a guy brought in a transmission tailshaft housing for a car made in the 40's. It was pretty lightweight, so I figured it had a lot of magnesium in it. Built a back plate to bolt it to, added a purge fitting, and ground out and fitted the smaller piece. I took it easy, took my time, did a root pass all the way around. A couple times, I could see it just start to flash. Then, had to have woodshop make a box to put it in, as an O2 purge for outer welding. Even then, a few times I observed slight flashes. Kind of spooky, when you know what magnesium is capable of.

[@kalenji1439]

Awesome result, Just a quick thought, if you wanted a machined finish, you could use the lathe by mounting the work piece to the saddle of the lathe ( you can get creative with how you secure it, making sure it is safe of course) and hold a milling boring head to the lathe spindle to do the cutting. Obviously fettling it back into shape is entirely doable and in most one off jobs it's likely the quickest approach, and the result you got was a true testament to your skill with hand tools.

[@catsupchutney]

I'd love to see a show where masters like abom79, This Old Tony and Keith Fenner etc offer their opinions on how to approach various repairs.

[@randomentity6553]

As a machinist who can weld, I'd have made a new part out of solid, or welded on a new tube

[@Sicktrickintuner]

I would have just made a new one. Much faster and easier

[@davidyisrael007]

LOL... You think abom is a master you never set foot in a shop before.

[@wrangler5729]

@@davidyisrael007 I agree 100%

[@bryanst.martin7134]

What!? We're not worth it!!! ;-) Just kidding, we definitely are and that would be sweet! Around '82 I knew an Air Force welder, that could weld soda cans together bottom to bottom. He fixed a few impossibles when the squadron really needed a miracle.

[@topidrut1]

You showed how you do it, not how it has to be done. I can't understand all the advice in the comments. I also fix various things and do YT and I know comments about my work, eg "You should buy a new one" but you said that it is terribly expensive. Glad to see your material, good luck with further repairs and YT. Greetings from Poland

[@RoadRunnerMeep]

This is why I llove fabrication and welding, you can make something or repair it with the right knowledge. Amazing work

[@charliemckay6402]

Amazing hand-eye coordination to build up the aluminum and never snag the steel plug. The overall shop was never shown but with the skill level of welding, a larger 14" gunsmith lathe and a standard size universal mill would fit in nicely. A universal mill would finish the bore and turn the weld in a matter of minutes by hanging the repair part over the edge of the table, swinging the head over the work, and using a boring head.

[@jameswyatt1304]

Nice work by a skilled TIG surgeon. Laughed a lot at the guidance to avoid pitting the steel or it'll be *really* hard to remove.

[@thelakeman5207]

In aerospace, with all the welding on that, we'd do a local stress relief. Aluminum is usually 325 degrees for 2 hours. That relaxes the grain .

[@DanielBoone337]

That's pretty nucking futs brother!!! I weld and pipe fit but you good metal fab guys can pull off miracles...

[@tonytully4943]

That was awesome! When the video started I didn't think that was the direction the repair was going to go in. Definitely glad that I watched this

[@clinthansen469]

Watching you repair a TOCE exhaust is like the world's best surgeon saving the world's worst person.

[@downshift83]

oh wow...would you look at that........TOCE.... why am i not surprised!!!

[@Ryan_1997]

Been awhile since I’ve seen your work. Glad you’re still doing business man Stay blessed

[@BobMuir100]

Never welded anything in my life, nor likely too, this was amazing, fascinating, marvelous, throughly enjoyed the show now subscribed.

[@aukanmeister]

Tried this, it works! Outboard thermostat housing broke from corrosion. Built it up around a stainless plug. Steel is probably better. Since steel leads heat better than stainless.

[@phxbro1]

You did a nice job on fixing that item . Have you ever consider taking that finished product and making castings out of it and maybe even selling a few of them on Amazon

[@BITTYBOY121]

Good work man ! You could have still used your lathe to bore out the middle so its perfectly round, Here's how;- 01) Clamp a boring bar/boring head into your lathe chuck. 02) Remove the tool post from your lathe saddle/carriage. 03) Make a jig/support to secure the work piece to the lathe saddle/carriage. 04) Align the work piece so that it is in the correct height and position in relation to the boring bar/boring head that's in the headstock chuck. 05) Once everything is lined up 100% then adjust the the boring bar accordingly and start the lathe on a modest speed, slowly winding the lathe tool post carriage/saddle (which has your work piece secured to it) towards the revolving boring bar and carefully bore out the work piece to the required diameter. Hope this helps.

[@MrErViLi]

Genius. You should post a video on that technique. That would be super helpful for many people.

[@BITTYBOY121]

@@MrErViLi Thanks man !, Yes when I've got some spare time I shall make a video of boring a work piece out on the lathe. as if you own a decent size lathe you can use it to do lots of jobs other than turning...

[@franktaylor7617]

Nice work. Sometimes the most challenging part is trying to figure out HOW to actually fix it. Not just the welding. Thanks for sharing your ideas. 👍🤘👊

[@andrew_koala2974]

The Fabrication Series Without doubt, this is an example of professional workmanship, and forward planning. In addition, the video production is excellent and way above many atrocious productions with poor narration. Perfection is not achievable ... The best one should strive for is 'Excellence' as taught to me by my Engineering Mentor. Even I learned something from your work and experience. So I thank you for that. This earns a Thumbs Up and a subscription Ignore the 'Nay-sayers".

[@BloopTube]

Perfection is a goal, but nothing else.

[@hardcore10987654321]

That's some really great work! As a beginner welder it's left me a lot to aspire to.

[@tonygallo8570]

That was very well done good for you and now you don't have to wait for a part

[@kansascowboy5721]

Man that’s cool, I think most people wouldn’t of attempted to do what you did! Excellent craftsmanship brother 👍🏻

[@princerechebei12]

So satisfying to see him build it back up

[@josephsmithe5774]

Super satisfying watching this video. I really want to practice doing this kind of welding with my powertig.

[@danielclowser2439]

You ROCK Bro! A horizontal mill would be perfect if ya had one laying around.

[@anthonylevan7508]

You appreciate us watching and we appreciate you sharing - thank you.

[@littlephilo585]

I think your hands have some built in CNC program. Something to be proud of there. I love your pride in finish.

[@silentvoiceinthedark5665]

Very nice narration, glad you dont have any funky dunky music. You have talent with welding and narration. Good for you

[@davidmcduffie1398]

Great job Justin. The repair looks really good. Another happy customer !

[@diaboloavocado]

I wouldn't have thought it could be repaired but it came out great.

[@josephkingston9252]

A grand craftsman, knows his craft well.

[@kevinlwiltfong7941]

Congrats! You have achieved Metal God Status!

[@Sleepyjackable]

Sick, pretty good idea machining down that form to weld over.

[@oldoldpilgrim7898]

That was a beautiful thing to watch.

[@Lifesabishi]

Thank you for imparting knowledge on us. I learned to weld aluminum because of your help all that time ago

[@kevinw3030]

You sir, are one slick fixer. I loved watching this!

[@dhanwatiesukhai2524]

Thank you very much for coming back. Awesome repair.

[@captainboggles]

simple straightforward repair, nicely done but comments full of criticism, overcomplicated advice and just plain negative vibes . everybody knows better ... not

[@bertodiy]

because they have no skills to do that!

[@xav1uz]

yup thats basically every comment section on welding videos

[@RadDadisRad]

Sometimes the easiest solution is the best solution. We’re not reinventing the wheel. Filling in the missing material was definitely the best solution because any other option would have taken up more material, more equipment and more time. All of which add up to more money.

[@tatertots-n-soup]

Not to mention possibly needing to order stock. Making it a multi day job instead of a few hours

[@mrmidnight32]

Can you test carbide vs diamond coated end bits for aluminum prep? I was told diamond lasts 10x longer, cuts cleaner and is half the price as a carbide tip. But I don’t see many people use them for aluminum work.