I am surprised that the quarry doesn't have a replacement part to get back to production and have you repair the broken part for a backup when the next one breaks. They already know that they are going to break since you already repaired one. It doesn't matter how expensive the part it since I can guarantee it will cost them more in lost production to not have a spair.
I’m 67 retired certified welder/fabricator.. I’m impressed with your smooth gouging strokes means less grinding! Impressed with your fit up! I’m like you I hated grinding. When I first began welding I cussed the grinding! An old timer told me learn how to use the cutting torch right! So he showed me what I was doing wrong. From then on I used my head. I tried to use the gouged as if it were a milling machine,,,,,,,less grinding! Graduate of “The School Of Hard Knocks”! Thank you for your videos!
"If you don't feel uncomfortable, you aren't growing" Thanks for walking us through this beast of a job, I really appreciated hearing your thoughts and concerns and how you worked through them.
An old toolmaker told me years ago “ some day they will bring you a job. No one else will want to attempt it. You won’t know how to do it but you start any way. While you are working on it you won’t be sure if you are doing it correctly. When you are finished you won’t know how you did it but it will be right and your best work”. Very well done sir, Mike
I found it refreshing to hear you find an old repair weld and understand that it was probably not made in ideal conditions. It is easy to be a critic but it is much better to be understanding. I take pride in my work and I like to see others take pride in theirs, but I was not always good or had good options, so I have less than ideal work out in the world but I try to learn and grow as a technician and now a trainer/ supervisor.
So easy to criticise jobs done by others. I use to be like that when i saw poor welds here and there, and im not near to be a competent welder myself. When doing my welds, this actitude came back to hout me. Id rhink about someone else critising my job, bot being aware of the cheap equipment, working off grid andwith shitty rainy cold weather. This video and your reply, Brett, gave me so much peace.
@jaimemanerodelpino634 Better to give the guy before the benefit of the doubt with sub-optimal equipment or perhaps trying to do it on-site with a lack of equipment. It's not going to get the job done faster if you are cross with someone who isn't there to hear you cursing.
I'm curious as to the history of the previous patching, was it days or months old? I won't say repair as it looks like it was intended to mitigate existing cracking.
being a heavy machinery mechanic that does field work i really appreciate and admire your attitude towards not judging other people’s welding because you are so very correct and you have no idea what situation they may be in so i appreciate that.
Years ago a fella in our works work shop said always wear a mask when grinding , when I asked why he replied use a grinder at night with a big spot light to see how much nasty stuff come off from the disk - grinding process . I did as he said , now I know what he ment and why you should always wear the mask as you dont want to breathe the nasty stuff . Great video by the way I'm going to come back to see what you and you channel does next .
Hey Allistair, I noticed the video says you wear ear plugs all day. If you're using the foam ones you need to look into getting custom fitted ones made to match your ears. They put so much less pressure on your ears/canals. My ears used to hurt and ache from wearing the foam ones all day until I went custom fitted. They block more noise and they hurt a lot less! I can't even imagine how much your body gets broken down doing job like this. I do machine work and it's amazing how sore you can get just standing in front of machines on concrete floors all day. Add to it the raw physical effort you have to put in....Hats off to ya. Recharge your batteries when you can. Looking forward to the second video.
Retired Brit Boilermaker here... I thought I'd done some "heavy engineering", but you've taken the term to many levels above that. I know what you're facing. Holy crap, Batman! And I'm only 8 mins in! I am sooo glad I'm out of the game. 17:35 Not enjoying it, I've had almost similar stress on jobs, with unknown metals... (Typing this as I watch). 22:30 I've had almost 100% success on cast steel using 316L stainless MMA up to around 1". Your analysis is pretty much spot on. Hope you've added a few zero's to the end of the bill for this monster.
Thanks for the transparency with the amount of stress you experience doing such a project. I thought i was alone with loosing sleep on project that are way out of my league (or I think they are). Good for your for challenging yourself and setting the bar higher.
Love the fact that you mentioned Kurtis and Karen. CEE. Also I felt for your hands, I laboured on a site once, separating temp cabins on school grounds and for three days after I couldn't even hold a spoon. I love your drive and vulnerability over this job and others I've watched. A working man if ever there was one. Respect
I hope that your adding in " the human factor" helps people realise there is much more involved than just glueing two bits of metal together. Awesome video, can't wait for part 2 👍
really respect the consideration of the previous welders work. shows you understand the field work and how hard it can be! the customer will always want an easier / quicker repair but sometimes its the bad choice in the long run!
I really have a lot of respect for how serious you take your craft. You may not be an a trained engineer, but you clearly have mastered your craft. It's clear you're knowledgeable, experienced, respectful of others. Thank you for sharing.
I really enjoyed that 55 minutes. What puts you in the same league as Issac and Kurtis is that you care about the job, as they do. I can tell that you care by how you still get nervous as you take on a new job, even with all your experience. I hope your employers and customers realise how much of you is invested in each job. 👍 BTW I bet that broke with a hell of a bang, probably a code brown for the operator 🤣😂🤣
Gives credit to others and doesn't put people down shows your true character and how much a craftsman you are and understand not everything is perfect in the field I enjoy watching and learning
Stress is a part of why we do the jobs nobody will touch, keeps you awake at night but alive in the day and enjoying the job, it's the buzz that feeds the fire. Hard graft in every move you make and thinking all the while. You quoted the list of my welder fabber channels I watch every week and yours is on that list. Thanks for the insight. Cheers
Stress can also kill you, no job is worth sleepless nights, been there, done that, now on 3 tablets a day for the rest of my life, I've seen that look on Alistair's face and the look in his eye's, not worth it if iam honest
You could also be on tablets every day and never done a damn thing in your life, I have seen a lot of it, it's very hard to know what could have been or what might have been. Hope your getting to take it easy now, all the best to you anyway.
The sheer weight of the machinery is 😳, hats off to you all you guys who work on these heavy duty machinery. 700tonnes of rock crushed per hour, wowzers! What a great job imo. I naturally have an interest in this and enjoy learning.
I literally started crying when I heard him say " I hear this noise in my nightmares". Just about fell out of my chair. I'm so sorry for those arms dude.
Wow, just WOW! I have watched nearly all of your repair videos since you've been uploading them. I am truly inspired by your work ethic. And this one, where you came on in the beginning and expressed your feelings was the best! I understand all too well about these monumental jobs. You see it, and know you're capable of accomplishing it, but the trauma comes by knowing precisely beforehand the amount of mental and physical pain that it will require of you. And I could feel it with you when you spoke at the camera about all the things running through your mind. Your determination and discipline are such a bright, shining inspirational example for anyone, anywhere struggling with anything. Thank you so much for sharing this with us!
Colossal job and you are a brave man for getting involved - thats a staggering amount of work in Assessment, analysis,calculation, procedure, prep and well what more can be said -I hope the money is worth the stress 😬I know its about the love of the challenge and the job and money is secondary but the stress is like each job takes a bit of you!!!! 🙏🙏🙏🙏👍
Excellent fitup. The things that set you apart from the others, is that you are not afraid to take on the big stuff. And you take the time to figure out how to weld it the correct way. Excellent work as always.
Thank you for sharing your time with us. It was a real pleasure to hear your comments on not knocking someone else's work, that happens too frequently and as you say you do not know the situation or the tools they had at hand. Really enjoyed the 55 minutes, it flew past, will be watching your follow up videos and catch up with previous work you have done. Have a great day Sir.
Wow buddy , I don't know what to say. I don't deserve this I feel I should give some to charity. Humbled, thankyou very much. Be sure to call in if u ever this way. All of you guys keep me going, some powerful comments and tokens. Thankyou again
@allistairc123 use this for your channel. I don't know, take the wife out to dinner. Enjoy yourself. With what you do, and how hard you work, you deserve it. Enjoy.
For future reference: If the XRF gun is not available a foundry should have a spectrum analyser you could put a small (25mm x 25mm x 10mm) chunk on to get an idea of the alloy used. (the bench top units deal better with carbon steels)
Having worked around LARGE and small pressure vessels ...a welders life is 10% welding and 90% gouging and grinding ...using a 100 ton crane always makes me hope a chain does not decide to break on me !
Your worries are completely understandable ; the pressure is on YOU . Repairing is always a risk . In our shop we make sure the client understands the stakes and they make the decision . We guarantee the quality and the effort but not the results .
Yes, it's got to be arranged so that the customer understands the risks, that the work has to be paid for more or less regardless of the result & is kept constantly updated on how the repair is progressing & what decisions have been made about the repair process & gets to agree & accept full responsibility at every step of the way. That jaw casting design looks a bit iffy to me.
Loving this project - I used to be the welding / NDT inspector at the Workington steelworks, west cumbria, so can really appreciate the amount of graft to achieve this kind of repair on very large highly stressed kit - In fabrication this is as tough as it gets ATB Dave
I've been welding over 35 year's my first thought would be that that couldn't be repaired as you said the thought of that failing as soon as it went back into the crusher that is definitely the difficult of the most difficult jobs you could ever get definitely well done 👏
When I was welding back in my hay days lol, I found that using 309 Stainless was the best for working on most Cast steel items even really poor castings. But always pre-heat and gradually bring the temp down after welding using what ever means possible.
It’s always tougher to repair these kind of things that it was to make it and that’s not to say it was easier task, but you don’t know what you’re starting with other flaws and faults and the casting process and the toughest part is you have no crystal ball to predict the outcome I have worked in foundries and fab shops, my whole life you have some amazing skills and I respect the amount of forethought and studying you put into this project before you even started to repair it. Bravo.
The most enjoyable UA-cam video I've watched in a long time. As a young fellow welder I have learned a lot, and I know I have way more to learn. Your videos have helped me a ton. Found you shortly after starting a job at a stone quarry in Canada, and I remember my first big welding job. The nerves, lost sleep and thinking there is no way that can be welded and ever hold. Guys at work laugh at me wondering around just looking at a job wondering what I'm doing. I am no where on this scale of repair, but someday I might get asked to do something like this. Keep up the great videos and I love all the details about what you look for and how you learn stuff, very informative and interesting. Cant wait for part 2.
After the disassemble and cleaning, after the study and consumable selection. After the surface preparation and line up. You are left with experience, skills and talents. You are a Master of your craft. From a jack of trades and master of none
I think the emotions you felt Alistair where quite justified, The amount of stress these jaws go through is incredible, enough to stress even the best of welders out i think, but ive seen your previous work and if any one can its you. Drink plenty buddy.
I've only done a few repairs on this kimd of scale. I probably would have done an initial test fit, and then welded on some sort of alignment bars on the sides to make sure I got it back together in exactly the same place. I'm amazed it fit up so well considering how much material you hogged off. Awesome job man. These are the kinds of jobs that keep you up at night, but they are also the kind you can be the proudest of when you get them out the door.
Thank you for the video its amazing what tech schools don't teach one', you are very good at what you did with showing the re fitting of both parts to be welded and the way you looked at which way the bevel need to go .
Enjoyed every minute of that! I can only imagine the stress of planning such a massive job with so many variables. Can't wait to see it all put back together. You are an outstanding craftsman...thanks for taking the time to share your work with us amateurs!
Foundry guy here, that pocket in the center web is likely piping shrink caused by a hot spot. I would guess that was under a very large riser and contact. Steel is pretty hard to pour clean just looking at the casting it looks pretty Chinese or Indian? Very large parts ALWAYS require salvage welding before leaving the Foundry for X-ray and other NDT. Basically what you are doing is an extreme cast salvage weld. Super cool process.
I repaired a small Chinese swing jaw a few years ago. It lasted about 3 months, the same length of time it took for the new bit took to get to us. Your jobs are way bigger than mine. I too hate the grinding. I have enjoyed your videos, you are a real champ
I am retired now, but was a union construction worker for over 40 years. I cared about my work, and worked hard even at 68 years old. That said, I can see how much you care about the results of your work. My hat is off to you. Thanks.
What a monster job! Thanks heaps for posting, can’t wait for part 2! You’ve always got some of the best shots of the gouging etc. it feels like I’m standing there with a helmet on.( minus the scalding temperatures) I’d never thought about the stresses on you mentally, I hope your customers appreciate the effort that you’ve going through to get their machine back in service.
Alistair, everything you do on your channel is fantastic and I love it when you’re with your uncle or your father and we have the privilege of hearing about things they have seen and done throughout their lives I personally think knowledge of this kind is invaluable and should be documented in any way possible…. Huge respect and ❤for you and your family’s dedication and hard work
One way to secure your bread is to do things that nobody else will do ... and do them well! I get what you explained about the stress, but in truth you'd probably look far and wide for a man who would take over that job and do it better! Thanks for telling the story!
I enjoyed the video, I work offshore. Three years ago I saw a Driller pull and twist a top drive in two. A team of welder took it apart and prepped it and welded all back together. It has a massive spindle inside the housing that was broken too. They welded it and line bored it back to spec to except the bearings. A new top drive was two months out. The job went better the anyone expected. Bad casing was the culprit.
I've watched a few big machine repairs in Pakistan , I cannot imagine doing that without the aid of modern machinery , even with all the gear your the man .
I know it adds a layer(s) to interfere with dexterity but wear a pair (or even two) of the orange criss cross gripper gloves. It slows down the onset of grinder numbness for me. Awesome processes, Allistair, love what you do.
watching this while playing the switch, just remembered that holding things hurt and realized how round I am. I miss this kind of work and appreciate the people still doing it.
.......G'day, after 20 years in the Mining industry as a metal worker I can vouch for the noise of those gougers. The boilermakers maxim "cut your way in, weld your way out". Bored? Asleep? Nah mate, love your videos. They show the brutal reality of the forces involved in the process of raw material. Kind regards, Malcolm.
This was an issue before it came to you to fix! You get to try a second time. Borrowing or renting a spark tester or PMI gun is good. Also, you can buy a mini Brinell hardness tester fairly cheap which can tell you a lot about how hardenable the piece is. Cast is always difficult and how much carbon you are dealing with tells you a lot. You do a very nice job balancing the practical vs the technological. In the end it’s all about did it work and will it last. Finally, you doubt yourself too much! You do awesome work! Sleep well! You got it!
Men of steel! My hands and shoulders are killing me just watching. I used to work in the steel industry, so I know tough, but you guys are next level. I hope you make a shitload of money, because you earn it 100%. Respect!
One time I worked on a BIG punch press . it was being scrapped but still worked ... It was twice the size of this unit, and made of cast iron ... it had been BRAZE WELDED together back in the 1950's ... On of the old guy told us they preheated it with everything they could get their hand on, for three days! and 6 men brazed it back together while another three guys kept heating it.
Mad work 🤯I've spent a lot of time prepping steel for welding with a 9" grinder and I can honestly say that cubitron grinding discs from 3m are something special 👌👌 expensive but Jesus they go good . Keep up the great work look forward to the welding side of it 👍 and good luck 🤞
Around 22min must be a relief to see it didnt rip a part out of the cast iron. definitly going to watch the rest of the video somewhere in the weekend.
Masterpiece. Stayed to the end. Fascinated by the process. Always amazes me the scale of these projects. There can't be many places that would take this on. Looking forward to the next phase. I watch Isaac and Curtis. Karen makes top class videos. And her editing work is superb. With Homey security. Their shop is about 2.5 hour drive from my house. I can see why you would stress over this repair. The size and forces involved are colossal. And this being a cast piece. I would have assumed it was junk.
This brings back memories of a similar repair carried out on a jaw when I worked in The Regional Engineering Workshop for ECC Quarries in the 1970's , the welders worked on it solid for about 2 0 days. It wasn't broken completely in half as yours is, a very large crack.
That’s one massive job you got on your hands. What kind of gloves do you use when you’re grinding? There are anti-vibration gloves to mitigate all the vibrations you’re getting. Tegera pro 9182 might be good fit for you. Love Therese kind of videos your posting 🤘
Have you tried the 3m Cubitron grind discs, they are very aggressive at material removal, they legitimately save 20% grinding time or more. They're not cheap but very fast and well worth it when you have a lot if grinding to do.
@@eweunkettles8207 Pferd are hard to get over here in Ireland, If i can't get 3M cubitron I get a Tyrolit disc called Cerabond X which is pretty good too, Tyrolit also have a disc called Rondeller which is really good for millscale.
I worked for TTX railroad cars as a welder, running wire over 375 amps building up worn down pivots on the trucks that holds the train wheels, man that was hot,! I really am in amazement on the amount off heat you will endure welding inside on those webs, maybe a camera to help you see inside to better weld the root passes, Great Channel, "turn up the heat and "keep it going" !! Thanks
Recent subscriber generally more into the tractor content but I found this engineering/welding project really interesting and very much looking forward to seeing part two 👍🏼
A crack was found in a tiller arm for my ship (part of the steering gear). It was probably around one ton. Once the repairs were made it was stress-relieved. While it was still pretty warm, it was loaded on a wooden pallet. When lifted off we found it had branded the pallet! Yeah, it was pretty warm when loaded on that pallet.
Thank you for the videos sir. When the fear suddenly kicks in when you're lying in bed. know the feeling - why didn't I just say no hahaha The owner of the machine is lucky to know you. Looking forward to part 2. All the best hope your Dad and Uncle Drew are doing well
They bring it to you - because they know you can do it! Love your videos!!! I was thinking that at least with this repair you wouldn’t end up “INSIDE” the repair like you were with the car crusher repair…. BUT…. As I watch the video, I can see that you are going to have to be a contortionist….
Great video as usual. You are a true master and have the biggest b--s in the industry for taking on a job that size. Can’t wait to see the next episode. Thank you Raymond 🏴👍👍
i find it really hard to switch off my mind from thinking about work, but a while ago i had some really great advice from a bloke who said to me 'just press pause in your mind'. sounds weird but it actually works, i leave work and think 'pause that' and it helps me switch off.
Had a contractor who used that to discourage a customer on a job they didn’t want to do , Quoted a figure easily several times more than it was worth . It didn’t work due to their outstanding reputation , the customer approved anyhow , NOW they had to do the job perfectly to justify the price and protect their reputation.
I kept looking at the time and thinking man I hope he doesn’t skip the fit up and welding. Very glad to get a part 2 or fingers crossed even a part 3 of this one. Great video 🤘🏼🤘🏼
Fixing that should be illegal. You know they have the money to buy a new one or pay you to build a whole new one out of AR550 or something beef and easier to fix.
I am so impressed, well done, I totally understand and people really don't understand the STRESS that some jobs bring. Biggest things I've done is a boat lift and a container lift, I'm now 60 n people still look to me to sort there shit out, Bless ya, good luck to you n yours for the future. X
I am surprised that the quarry doesn't have a replacement part to get back to production and have you repair the broken part for a backup when the next one breaks. They already know that they are going to break since you already repaired one. It doesn't matter how expensive the part it since I can guarantee it will cost them more in lost production to not have a spair.
I’m 67 retired certified welder/fabricator.. I’m impressed with your smooth gouging strokes means less grinding! Impressed with your fit up! I’m like you I hated grinding. When I first began welding I cussed the grinding! An old timer told me learn how to use the cutting torch right! So he showed me what I was doing wrong. From then on I used my head. I tried to use the gouged as if it were a milling machine,,,,,,,less grinding! Graduate of “The School Of Hard Knocks”! Thank you for your videos!
"If you don't feel uncomfortable, you aren't growing"
Thanks for walking us through this beast of a job, I really appreciated hearing your thoughts and concerns and how you worked through them.
An old toolmaker told me years ago “ some day they will bring you a job. No one else will want to attempt it. You won’t know how to do it but you start any way. While you are working on it you won’t be sure if you are doing it correctly. When you are finished you won’t know how you did it but it will be right and your best work”. Very well done sir, Mike
I found it refreshing to hear you find an old repair weld and understand that it was probably not made in ideal conditions. It is easy to be a critic but it is much better to be understanding. I take pride in my work and I like to see others take pride in theirs, but I was not always good or had good options, so I have less than ideal work out in the world but I try to learn and grow as a technician and now a trainer/ supervisor.
So easy to criticise jobs done by others. I use to be like that when i saw poor welds here and there, and im not near to be a competent welder myself. When doing my welds, this actitude came back to hout me. Id rhink about someone else critising my job, bot being aware of the cheap equipment, working off grid andwith shitty rainy cold weather. This video and your reply, Brett, gave me so much peace.
@@jaimemanerodelpino634 Been there, done that.
@jaimemanerodelpino634 Better to give the guy before the benefit of the doubt with sub-optimal equipment or perhaps trying to do it on-site with a lack of equipment. It's not going to get the job done faster if you are cross with someone who isn't there to hear you cursing.
well said
I'm curious as to the history of the previous patching, was it days or months old? I won't say repair as it looks like it was intended to mitigate existing cracking.
being a heavy machinery mechanic that does field work i really appreciate and admire your attitude towards not judging other people’s welding because you are so very correct and you have no idea what situation they may be in so i appreciate that.
Years ago a fella in our works work shop said always wear a mask when grinding , when I asked why he replied use a grinder at night with a big spot light to see how much nasty stuff come off from the disk - grinding process . I did as he said , now I know what he ment and why you should always wear the mask as you dont want to breathe the nasty stuff . Great video by the way I'm going to come back to see what you and you channel does next .
Yes the noise is frightening, I used to do similar work on fork truck weight's 50 years ago. also the smoke, not a nice procedure
you do some amazing work
Hey Allistair, I noticed the video says you wear ear plugs all day. If you're using the foam ones you need to look into getting custom fitted ones made to match your ears. They put so much less pressure on your ears/canals. My ears used to hurt and ache from wearing the foam ones all day until I went custom fitted. They block more noise and they hurt a lot less! I can't even imagine how much your body gets broken down doing job like this. I do machine work and it's amazing how sore you can get just standing in front of machines on concrete floors all day. Add to it the raw physical effort you have to put in....Hats off to ya. Recharge your batteries when you can. Looking forward to the second video.
Retired Brit Boilermaker here... I thought I'd done some "heavy engineering", but you've taken the term to many levels above that. I know what you're facing. Holy crap, Batman! And I'm only 8 mins in! I am sooo glad I'm out of the game.
17:35 Not enjoying it, I've had almost similar stress on jobs, with unknown metals... (Typing this as I watch).
22:30 I've had almost 100% success on cast steel using 316L stainless MMA up to around 1". Your analysis is pretty much spot on. Hope you've added a few zero's to the end of the bill for this monster.
Thanks for the transparency with the amount of stress you experience doing such a project. I thought i was alone with loosing sleep on project that are way out of my league (or I think they are). Good for your for challenging yourself and setting the bar higher.
Thank you so much for sharing this type of repair. Not only is it educational but it lets a younger generation see what type of work is out there.
Younger generation not want work like that don't know how things will get repaired after our generation gone
Seeing an open bucket of 200 gouging sticks slowly get smaller and smaller gives a sense of scale to the amount of prep to be done!
Half inch non the less
He should have just used epoxy resin and gaffer tape. Would have been a whole lot quicker.
Wow Ken can't stop laughing 😂. Hey didn't they use that on the Space Station too. Ha ha.@@KenFullman
As a fabricator I found this very interesting. Can’t wait for the welding one. Much appreciation for putting these out.
Love the fact that you mentioned Kurtis and Karen. CEE. Also I felt for your hands, I laboured on a site once, separating temp cabins on school grounds and for three days after I couldn't even hold a spoon. I love your drive and vulnerability over this job and others I've watched. A working man if ever there was one. Respect
I hope that your adding in " the human factor" helps people realise there is much more involved than just glueing two bits of metal together. Awesome video, can't wait for part 2 👍
really respect the consideration of the previous welders work. shows you understand the field work and how hard it can be! the customer will always want an easier / quicker repair but sometimes its the bad choice in the long run!
I really have a lot of respect for how serious you take your craft. You may not be an a trained engineer, but you clearly have mastered your craft. It's clear you're knowledgeable, experienced, respectful of others.
Thank you for sharing.
To avoid nightmare jobs....stop being a master at what You do :)
Oh how true!
Indeed
😂 so true, when you’re good you get all the shit jobs no one else can do
@rolfmissing4554 I'm a master at my work also! Master Fugcup sometimes but I'm a Master nonetheless🤔😜
I know a guy who is a Master Baiter. He does a lot of jobs, all by hand.
Super cool and down to earth! Thank you for taking the time to show us your work.
Absolute legend thankyou for the support buddy, you guys keep the show on the road!!👍🏻👍🏻
I really enjoyed that 55 minutes. What puts you in the same league as Issac and Kurtis is that you care about the job, as they do. I can tell that you care by how you still get nervous as you take on a new job, even with all your experience. I hope your employers and customers realise how much of you is invested in each job. 👍
BTW I bet that broke with a hell of a bang, probably a code brown for the operator 🤣😂🤣
i watch curtis who is issac? so i can have a look
@@simonhughes3705 @ICWeld
Ic weld
I thought is was Kurtis?
Curtis is cutting edge engineering
I was a welder for 40 years wore out a lot of grinders I know the feeling in your hands
Gives credit to others and doesn't put people down shows your true character and how much a craftsman you are and understand not everything is perfect in the field I enjoy watching and learning
Stress is a part of why we do the jobs nobody will touch, keeps you awake at night but alive in the day and enjoying the job, it's the buzz that feeds the fire. Hard graft in every move you make and thinking all the while.
You quoted the list of my welder fabber channels I watch every week and yours is on that list. Thanks for the insight. Cheers
Stress can also kill you, no job is worth sleepless nights, been there, done that, now on 3 tablets a day for the rest of my life, I've seen that look on Alistair's face and the look in his eye's, not worth it if iam honest
You could also be on tablets every day and never done a damn thing in your life, I have seen a lot of it, it's very hard to know what could have been or what might have been. Hope your getting to take it easy now, all the best to you anyway.
The sheer weight of the machinery is 😳, hats off to you all you guys who work on these heavy duty machinery. 700tonnes of rock crushed per hour, wowzers! What a great job imo. I naturally have an interest in this and enjoy learning.
I literally started crying when I heard him say " I hear this noise in my nightmares". Just about fell out of my chair. I'm so sorry for those arms dude.
Never ceases to amaze the size of the projects you take on
A "scientific test" that involves a sledgehammer?
A man after my own heart, right there
Wow, just WOW! I have watched nearly all of your repair videos since you've been uploading them. I am truly inspired by your work ethic. And this one, where you came on in the beginning and expressed your feelings was the best! I understand all too well about these monumental jobs. You see it, and know you're capable of accomplishing it, but the trauma comes by knowing precisely beforehand the amount of mental and physical pain that it will require of you. And I could feel it with you when you spoke at the camera about all the things running through your mind. Your determination and discipline are such a bright, shining inspirational example for anyone, anywhere struggling with anything. Thank you so much for sharing this with us!
Colossal job and you are a brave man for getting involved - thats a staggering amount of work in Assessment, analysis,calculation, procedure, prep and well what more can be said -I hope the money is worth the stress 😬I know its about the love of the challenge and the job and money is secondary but the stress is like each job takes a bit of you!!!! 🙏🙏🙏🙏👍
The amount of force that took to break! God, impressive stuff.
Excellent fitup. The things that set you apart from the others, is that you are not afraid to take on the big stuff. And you take the time to figure out how to weld it the correct way. Excellent work as always.
Thank you for sharing your time with us. It was a real pleasure to hear your comments on not knocking someone else's work, that happens too frequently and as you say you do not know the situation or the tools they had at hand. Really enjoyed the 55 minutes, it flew past, will be watching your follow up videos and catch up with previous work you have done. Have a great day Sir.
Really appreciate what you do. Awesome channel. Thank you, keep at it.
Wow buddy , I don't know what to say. I don't deserve this I feel I should give some to charity.
Humbled, thankyou very much.
Be sure to call in if u ever this way. All of you guys keep me going, some powerful comments and tokens. Thankyou again
@allistairc123 use this for your channel. I don't know, take the wife out to dinner. Enjoy yourself. With what you do, and how hard you work, you deserve it. Enjoy.
@@allistairc123 you most definitely do! crazy amount of work this. Big respect !
After watching both vids a few times,
i see a place I would have wanted to START my career in welding/fab/repair.
For future reference: If the XRF gun is not available a foundry should have a spectrum analyser you could put a small (25mm x 25mm x 10mm) chunk on to get an idea of the alloy used. (the bench top units deal better with carbon steels)
Having worked around LARGE and small pressure vessels ...a welders life is 10% welding and 90% gouging and grinding ...using a 100 ton crane always makes me hope a chain does not decide to break on me !
Your worries are completely understandable ; the pressure is on YOU . Repairing is always a risk . In our shop we make sure the client understands the stakes and they make the decision . We guarantee the quality and the effort but not the results .
Yes, it's got to be arranged so that the customer understands the risks, that the work has to be paid for more or less regardless of the result & is kept constantly updated on how the repair is progressing & what decisions have been made about the repair process & gets to agree & accept full responsibility at every step of the way.
That jaw casting design looks a bit iffy to me.
@@paulpaul9914I agree with you, it seems as though he found the problem.
I see the old melted torch is working well...Brilliant to watch true heavy industry at work.. stay safe lads..
Loving this project - I used to be the welding / NDT inspector at the Workington steelworks, west cumbria, so can really appreciate the amount of graft to achieve this kind of repair on very large highly stressed kit - In fabrication this is as tough as it gets
ATB
Dave
This one looks a lot better than the last one you fixed. Done and done already
I've been welding over 35 year's my first thought would be that that couldn't be repaired as you said the thought of that failing as soon as it went back into the crusher that is definitely the difficult of the most difficult jobs you could ever get definitely well done 👏
When I was welding back in my hay days lol, I found that using 309 Stainless was the best for working on most Cast steel items even really poor castings. But always pre-heat and gradually bring the temp down after welding using what ever means possible.
Incredible work. I can't imagine how you'll be able to get in around it to weld for hours at a time , not to mention the heat . Big respect
It’s always tougher to repair these kind of things that it was to make it and that’s not to say it was easier task, but you don’t know what you’re starting with other flaws and faults and the casting process and the toughest part is you have no crystal ball to predict the outcome I have worked in foundries and fab shops, my whole life you have some amazing skills and I respect the amount of forethought and studying you put into this project before you even started to repair it. Bravo.
The most enjoyable UA-cam video I've watched in a long time. As a young fellow welder I have learned a lot, and I know I have way more to learn. Your videos have helped me a ton. Found you shortly after starting a job at a stone quarry in Canada, and I remember my first big welding job. The nerves, lost sleep and thinking there is no way that can be welded and ever hold. Guys at work laugh at me wondering around just looking at a job wondering what I'm doing. I am no where on this scale of repair, but someday I might get asked to do something like this. Keep up the great videos and I love all the details about what you look for and how you learn stuff, very informative and interesting. Cant wait for part 2.
After the disassemble
and cleaning, after the study and consumable selection. After the surface preparation and line up. You are left with experience, skills and talents. You are a Master of your craft. From a jack of trades and master of none
The initial fit up of the two sections was pretty damn impressive. Nice work!
I think the emotions you felt Alistair where quite justified, The amount of stress these jaws go through is incredible, enough to stress even the best of welders out i think, but ive seen your previous work and if any one can its you. Drink plenty buddy.
I've only done a few repairs on this kimd of scale. I probably would have done an initial test fit, and then welded on some sort of alignment bars on the sides to make sure I got it back together in exactly the same place. I'm amazed it fit up so well considering how much material you hogged off. Awesome job man. These are the kinds of jobs that keep you up at night, but they are also the kind you can be the proudest of when you get them out the door.
Thank you for the video its amazing what tech schools don't teach one', you are very good at what you did with showing the re fitting of both parts to be welded and the way you looked at which way the bevel need to go .
Enjoyed every minute of that! I can only imagine the stress of planning such a massive job with so many variables. Can't wait to see it all put back together. You are an outstanding craftsman...thanks for taking the time to share your work with us amateurs!
Foundry guy here, that pocket in the center web is likely piping shrink caused by a hot spot. I would guess that was under a very large riser and contact. Steel is pretty hard to pour clean just looking at the casting it looks pretty Chinese or Indian? Very large parts ALWAYS require salvage welding before leaving the Foundry for X-ray and other NDT. Basically what you are doing is an extreme cast salvage weld. Super cool process.
Cool thanks bud always interesting to hear. You guys run gougers for salvage?
Stressed just watching you. Luckily, those days have gone for me. Stunning work. Stunning work ethic.. You have lucky clients.
I repaired a small Chinese swing jaw a few years ago. It lasted about 3 months, the same length of time it took for the new bit took to get to us. Your jobs are way bigger than mine. I too hate the grinding. I have enjoyed your videos, you are a real champ
Some phenomenal gouging shots in this. What a monster job!
I am retired now, but was a union construction worker for over 40 years. I cared about my work, and worked hard even at 68 years old. That said, I can see how much you care about the results of your work. My hat is off to you. Thanks.
What a monster job! Thanks heaps for posting, can’t wait for part 2! You’ve always got some of the best shots of the gouging etc. it feels like I’m standing there with a helmet on.( minus the scalding temperatures) I’d never thought about the stresses on you mentally, I hope your customers appreciate the effort that you’ve going through to get their machine back in service.
Alistair, everything you do on your channel is fantastic and I love it when you’re with your uncle or your father and we have the privilege of hearing about things they have seen and done throughout their lives
I personally think knowledge of this kind is invaluable and should be documented in any way possible….
Huge respect and ❤for you and your family’s dedication and hard work
It's just unreal the work thats going into that, Much respect!
One way to secure your bread is to do things that nobody else will do ... and do them well! I get what you explained about the stress, but in truth you'd probably look far and wide for a man who would take over that job and do it better! Thanks for telling the story!
I weld for a living & I'm feeling stress just looking at the initial pieces that landed in the workshop. I get your thoughts - that's large...
You tried Pferd grinding discs? They grind..
I enjoyed the video, I work offshore. Three years ago I saw a Driller pull and twist a top drive in two. A team of welder took it apart and prepped it and welded all back together. It has a massive spindle inside the housing that was broken too. They welded it and line bored it back to spec to except the bearings. A new top drive was two months out. The job went better the anyone expected. Bad casing was the culprit.
I've watched a few big machine repairs in Pakistan , I cannot imagine doing that without the aid of modern machinery , even with all the gear your the man .
I know it adds a layer(s) to interfere with dexterity but wear a pair (or even two) of the orange criss cross gripper gloves. It slows down the onset of grinder numbness for me. Awesome processes, Allistair, love what you do.
watching this while playing the switch, just remembered that holding things hurt and realized how round I am. I miss this kind of work and appreciate the people still doing it.
Unbelievable that this could be repaired. Great video explaining the process and stress involved in this job .💪
.......G'day,
after 20 years in the Mining industry as a metal worker I can vouch for the noise of those gougers. The boilermakers maxim "cut your way in, weld your way out". Bored? Asleep? Nah mate, love your videos. They show the brutal reality of the forces involved in the process of raw material.
Kind regards,
Malcolm.
This was an issue before it came to you to fix! You get to try a second time. Borrowing or renting a spark tester or PMI gun is good. Also, you can buy a mini Brinell hardness tester fairly cheap which can tell you a lot about how hardenable the piece is. Cast is always difficult and how much carbon you are dealing with tells you a lot. You do a very nice job balancing the practical vs the technological. In the end it’s all about did it work and will it last. Finally, you doubt yourself too much! You do awesome work! Sleep well! You got it!
Men of steel! My hands and shoulders are killing me just watching. I used to work in the steel industry, so I know tough, but you guys are next level. I hope you make a shitload of money, because you earn it 100%. Respect!
Takes a big man to take on a giant job like that good on you you've got what it takes no shortcuts great job no fear
This carefully prepwork leads to success.😊
The music give you a low-budget 1980's sci-fi movie vibe.
One time I worked on a BIG punch press . it was being scrapped but still worked ... It was twice the size of this unit, and made of cast iron ... it had been BRAZE WELDED together back in the 1950's ... On of the old guy told us they preheated it with everything they could get their hand on, for three days! and 6 men brazed it back together while another three guys kept heating it.
Mad work 🤯I've spent a lot of time prepping steel for welding with a 9" grinder and I can honestly say that cubitron grinding discs from 3m are something special 👌👌 expensive but Jesus they go good . Keep up the great work look forward to the welding side of it 👍 and good luck 🤞
Around 22min must be a relief to see it didnt rip a part out of the cast iron. definitly going to watch the rest of the video somewhere in the weekend.
Masterpiece. Stayed to the end. Fascinated by the process. Always amazes me the scale of these projects. There can't be many places that would take this on. Looking forward to the next phase. I watch Isaac and Curtis. Karen makes top class videos. And her editing work is superb. With Homey security. Their shop is about 2.5 hour drive from my house. I can see why you would stress over this repair. The size and forces involved are colossal. And this being a cast piece. I would have assumed it was junk.
You are a rare true craftsman that knows what he’s doing and I commend you sir!!!!
Heart like a lion.
That is a very big difficult project...Glad it's someone else's project and not mine...Can't wait for part 2
You are very brave.....
This brings back memories of a similar repair carried out on a jaw when I worked in The Regional Engineering Workshop for ECC Quarries in the 1970's , the welders worked on it solid for about 2 0 days. It wasn't broken completely in half as yours is, a very large crack.
That’s one massive job you got on your hands.
What kind of gloves do you use when you’re grinding? There are anti-vibration gloves to mitigate all the vibrations you’re getting.
Tegera pro 9182 might be good fit for you.
Love Therese kind of videos your posting 🤘
Have you tried the 3m Cubitron grind discs, they are very aggressive at material removal, they legitimately save 20% grinding time or more.
They're not cheap but very fast and well worth it when you have a lot if grinding to do.
yes a fantastic difference
pferd discs also good
most of the cheapies just make dust
@@eweunkettles8207 Pferd are hard to get over here in Ireland, If i can't get 3M cubitron I get a Tyrolit disc called Cerabond X which is pretty good too, Tyrolit also have a disc called Rondeller which is really good for millscale.
I worked for TTX railroad cars as a welder, running wire over 375 amps building up worn down pivots on the trucks that holds the train wheels, man that was hot,!
I really am in amazement on the amount off heat you will endure welding inside on those webs, maybe a camera to help you see inside to better weld the root passes, Great Channel, "turn up the heat and "keep it going" !!
Thanks
Recent subscriber generally more into the tractor content but I found this engineering/welding project really interesting and very much looking forward to seeing part two 👍🏼
A crack was found in a tiller arm for my ship (part of the steering gear). It was probably around one ton. Once the repairs were made it was stress-relieved. While it was still pretty warm, it was loaded on a wooden pallet. When lifted off we found it had branded the pallet! Yeah, it was pretty warm when loaded on that pallet.
Thank you for the videos sir. When the fear suddenly kicks in when you're lying in bed. know the feeling - why didn't I just say no hahaha The owner of the machine is lucky to know you. Looking forward to part 2. All the best hope your Dad and Uncle Drew are doing well
WOW that is IMPRESSIVE! You have some serious skill! Curtis too! What you both do is awesome!
They bring it to you - because they know you can do it! Love your videos!!!
I was thinking that at least with this repair you wouldn’t end up “INSIDE” the repair like you were with the car crusher repair….
BUT….
As I watch the video, I can see that you are going to have to be a contortionist….
I couldn't believe it sat on their straight the very first time you put it on, that was amazing. You're an artist, no doubt.
Great video as usual. You are a true master and have the biggest b--s in the industry for taking on a job that size. Can’t wait to see the next episode. Thank you
Raymond 🏴👍👍
i find it really hard to switch off my mind from thinking about work, but a while ago i had some really great advice from a bloke who said to me 'just press pause in your mind'. sounds weird but it actually works, i leave work and think 'pause that' and it helps me switch off.
How many AMPS to run those 1/2” carbon rods?
On the ribs, a beveler would have cleaned them up much faster and easier. But you did a good job with what you had.
You’ll have to start charging more money so they won’t bring them to you 😅
Had a contractor who used that to discourage a customer on a job they didn’t want to do , Quoted a figure easily several times more than it was worth . It didn’t work due to their outstanding reputation , the customer approved anyhow , NOW they had to do the job perfectly to justify the price and protect their reputation.
I kept looking at the time and thinking man I hope he doesn’t skip the fit up and welding. Very glad to get a part 2 or fingers crossed even a part 3 of this one.
Great video 🤘🏼🤘🏼
Fixing that should be illegal. You know they have the money to buy a new one or pay you to build a whole new one out of AR550 or something beef and easier to fix.
It depends on the lead time of getting the parts, 2 months is quicker than you could get a new part unless you're very lucky.
I am so impressed, well done, I totally understand and people really don't understand the STRESS that some jobs bring. Biggest things I've done is a boat lift and a container lift, I'm now 60 n people still look to me to sort there shit out,
Bless ya, good luck to you n yours for the future. X
from 14:01 you see some honesty that is very rare here on youtube, thumbs up for sharing the thoughts behind the struggle!