Need help....is this fixable???

[chevy292]

First off I am not a professional welder by any means. I can weld pretty well, I'm self taught. I have done some structural welds before and they are still holding up very well. I have a stick welder to work with.

Here is the problem I need help with. Looking at the damage, if i get this back into shape and welded is it going to be safe? I don't have the experience to know if the metal is going to be strong or if it is weakened beyond use.

 

[Lostalot]

I too am not an expert, but if it was my machine I would reposition it and weld it up then plate over the outside to strengthen it allowing pin access etc,but prior to this I would first ask an engineer mate definately showing him the photos as you have, alternatively you can fabricate a complete new end piece for that side so there are a few options..regards

 

[yomax4]

I would Heat it, Beat it and Weld the Snot out of it. You have nothing to lose if you try. ( maybe bevel before you weld.)

 

[chevy292]

I'm definitely going to try....a new boom is $1600...........YIKES!!!!!!!

What size plate should I weld on the outside to strengthen it? Should I try to get a piece of plate the same thickness? I have a piece of 1/4" plate but I'm not sure if it is thick enough.

Oh man, I just noticed the other side is split. Would I have to drill the ends of the crack to stop it from spreading?

 

[jake98]

Is that piston rod broken off in the third pic?

 

[chevy292]

Yup. When the side let go it tore the piston right off....

 

[Shield Arc]

I didn't wait until my pin holes failed, soon as they got sloppy I reinforced the pin hole on my FEL, and backhoe. I took some 2 1/2 inch cold rolled, and drilled a 1-inch hole in it, cut 1/2 to 3/4 inch thick washers and welded them in place. Cut all new longer pins.

 

[RobertBrown]

I guess it depends on how bad you need it. If your making the rent with that machine you better just cough up the 16 and get new pieces.
On the other hand...looks to me like the engineering was a liittle quick on that piece, somebody skipped a calc somewhere cause it was certainly the weak link.
You could re build it stronger than original if you had the time and the means/ methods.

 

[hodge]

That area has a tremendous amount of leverage imposed on it- testified by the breaks. I don't think that you can bend it back into shape and weld the snot out of it. It is already very weakened and compromised. I would disassemble the boom, straighten things up, and study it from that point- if it were mine, I would remove the bushings, look at the length of the pin, and rebuild and plate the sides with at least 3/8" steel, then build new collars and use a lengthened pin. A good welder/fabricator can do this. You might as well fix the weakness that caused the issue in the first place, instead of hobbling it back into the same shape that it was to begin with.

 

[crash325]

Push or pull it back in place.
Hammer bent / broken piece back - Watch for cracking or breaking - heat may help.
Clean all around.
Grind a shallow "V" then tack back in place.
Fabricate a sheet of 1/2" steel that fits around the pin.
Run you best bead around all sides.

It will be safe, but if you don't do a good job it will make a proper repair more costly.