Small roller repair

[4shorts]

Today we had a customer come in the shop dragging a 6 foot roller asking if I could repair it and right away. Seeing he is one of our best customers I said sure and dropped what I was doing and started in at it.

The end piece was completely off and it looked as if something jammed it up because it was blue with heat. The bearing didn't seize so it must have been something else that I wasn't sure of.

Problem number one was, My lathe was to short to swing this thing so I used a die grinder with a carbide rasp and removed the old welding on the side of the roller.

Problem number two was. How am I going to get the new shaft welded straight coming out from that pipe without a lathe? Well I got a brain fart and came up with what you see below.

I made the new shaft on the lathe. Then I machined two large washers. The inside one was 1/4" thick and the outside one was 1/2 " thick. Once I had all the machining done I put the machined items in the welding postioner and used the Millermatic 350P:cool2: on pulse for most of the welding.

I then took the part and fit it tightly into the pipe and welded it again. It took all morning to do it but the customer was sure pleased when he came back to pick it up.

I know. It's boring but I just wanted to post something :laughing:

 

[hawkeye08]

Nice job! What was it for?

 

[4shorts]

Nice job! What was it for?

I'm not sure but I think it was for a hay baler. He did say there was a big belt on the machine. Thanks

 

[Farmerford]

Seems a shame hide two of those beautiful welds inside the roller!

 

[4shorts]

Seems a shame hide two of those beautiful welds inside the roller!

Thanks Farmer. It's funny you said that because someone else said that in the shop today. Hum. Might be something to it . Thanks again for your post.

 

[gwdixon]

I know this is extremely rude to ask so ignore it if it exceeds common decency.

How much does a repair job like this cost the customer?

I only ask because your work is so admirable and professional that it is of considerable interest to know what skills at your level receive for compensation.

 

[Soundguy]

excelent work..

soundguy

 

[jayste]

Very nice repair, Paul! Looks like you're "brain fart" did the trick. Nice work with the lathe, positioner and welder!:thumbsup::thumbsup:

 

[wdchyd]

4shorts,

A Great Post is Never Boring!!!!.....Nice Work......Thanx for pics too....:thumbsup:

 

[MarkV]

I don't weld well enough to ever show it on TBN but if photo #5 is normal for you; YOUR THE MAN!

MarkV

 

[Soundguy]

you got that right. I'm a hack welder at best... that looks like it was FORMED that way!.. not welded..

soundguy

 

[gavinol]

Very nice repair,you doing grate job and lots of hardwork.

 

[4shorts]

I know this is extremely rude to ask so ignore it if it exceeds common decency.

How much does a repair job like this cost the customer?

I only ask because your work is so admirable and professional that it is of considerable interest to know what skills at your level receive for compensation.

I wouldn't say it's a rude question. I'd say it's just more curiosity than anything else
One of the things I have never done was talk pricing on any of the forums I visit but I will say that I charge my regular welding/machine fee per hour and I do get paid well for my work. If I have to drop what I have in the shop at the time and do something like this I do charge a little extra because it's changed my daily shop plans and put me behind for the day.
The customer I did that repair for has been with me for 15 years or more and his main goal is to get'er done no matter what.

That being said I always try and put 100% into it and although he needed this part ASAP I still wouldn't let it leave the shop until I was satisfied with the end result.
Great question and although I'm not sure if It really applies to me but very nice comments as well and I thank you for them :thumbsup:

excelent work..

soundguy

Thank you sir

Very nice repair, Paul! Looks like you're "brain fart" did the trick. Nice work with the lathe, positioner and welder!:thumbsup::thumbsup:

Thanks Jay. Every now and then I get a brain fart that works in my favor. I'll never post the ones that don't work :laughing:

4shorts,

A Great Post is Never Boring!!!!.....Nice Work......Thanx for pics too....:thumbsup:

Thanks my friend. I almost didn't post this. I said to myself "Who will want to see and old roller being repaired"? and then I said well why not. At least they get to see a little bit of the equipment if nothing else Appreciate your comment and I'm glad you didn't find it boring .

I don't weld well enough to ever show it on TBN but if photo #5 is normal for you; YOUR THE MAN!

MarkV

Mark we all have our weakness's and posting this stuff is just another way of learning how we do it. As with everything, practice makes perfect buddy. I may be doing this all wrong as well but it works for me and my customer.

Although welding is not my trade I've always been very cautious about my welds. Haven't had a weld break yet (knock on wood) :laughing: Thanks for your post and comments.

Very nice repair,you doing grate job and lots of hardwork.

Thank you very much. I'm happy to hear you enjoyed seeing it. Yep it was a bit of hard work. The customer needed it done right away and I think I used all the tools in the shop to get it done. Had a mess to clean up afterword's as well .

Welcome to Tractor By Net. Glad to see you here and I hope we'll get to see more of you. Thanks for your kind words :thumbsup:

 

[Egon]

Those are nice welds!:thumbsup::thumbsup::thumbsup:

 

[Craig Clayton]

I liked the powered rotator for welding. I do it the old fashioned way, I roll the piece and that is nasty chasing a pipe across the bench.
Craig Clayton

 

[4shorts]

Those are nice welds!:thumbsup::thumbsup::thumbsup:

Thank you my buddy!

I liked the powered rotator for welding. I do it the old fashioned way, I roll the piece and that is nasty chasing a pipe across the bench.
Craig Clayton

:laughing: I could see that being a problem alright. I used to use different ways as well but I bought the positioner and placed it on an adjustable hydraulic table and now it's heaven to use. Makes my bad welding look good :laughing: Here's a few more pics of the positioner. Thanks for posting

 

[varmint]

Paul- what is in that giant gray cabinet in the upper left of your last picture? Maybe a guest room?
Anyway, I don't see how those circular welds could have been any better! Not to be rude, since you elected not to share costs with us, but would you give us some idea about what your regular shop rates for fabrication work might be... As folks who sometimes pay for outside work, many of us are really curious what the "best" costs. I'd guess $100/hour would be reasonable, but perhaps I am off base and behind the times? Please don't take this question so much as a personal intrusion, but a teaching opportunity! Shops like yours are accessible to the average guy when absolutely needed, although pretty rare to find!

 

[Travelover]

Nice job and very creative. Your customers are lucky to have you as a resource.

 

[framer]

nice job excellent weld.and good business ethics.i noticed in another post you used miller 251 now 350 how to like it compared.looking to trade up from my 210 thanks.

 

[4shorts]

Paul- what is in that giant gray cabinet in the upper left of your last picture? Maybe a guest room?
Anyway, I don't see how those circular welds could have been any better! Not to be rude, since you elected not to share costs with us, but would you give us some idea about what your regular shop rates for fabrication work might be... As folks who sometimes pay for outside work, many of us are really curious what the "best" costs. I'd guess $100/hour would be reasonable, but perhaps I am off base and behind the times? Please don't take this question so much as a personal intrusion, but a teaching opportunity! Shops like yours are accessible to the average guy when absolutely needed, although pretty rare to find!

That room is a compressor room. I put the beast up there to have it out of my way and then built an insulated room around it. I put doors on it so it would be easier to service and it takes it's air from vents on the rear of the building. It's much quieter this way. I snapped a few photo's of it for your entertainment.

As for shop rates and by the way I'm not the best

I think rates are based on your area's economic situation. There are plenty of fabrication and welding shops around here. Some are OK at best and there are others that are terrible. I know more about the bad ones because I get to redo the stuff they didn't do right and I'm amazed how they can remain in business but some how they do.

I don't advertise my business. In 15 years I think the only money I spent on advertising was pens that I bought and was really talked into that. Some of the machine shops here are good at machining but are weak at welding so I get some of there welding. I have some jobs out there now that are from a foreign fishing boat that a machine shop dropped off to be tig welded. A reasonable hourly rate is around the $100. mark but they should be able to do very good work for that king of money.

I got into the metal working, welding and fabrication because of our customer needs. they needed it done so I built the business around there needs. We seldom take in outside work. after all I'm working by myself and 70-80 hour weeks should be enough for anyone. I just thank god for my wife. She handles all the paper work and phone calls.

Here's an example of shop rates. Here in Newfoundland we get around $60. per hour for vehicle repairs. We do a good bit of government work as well. In Fort Mc.Murry, Alberta the hourly rate for the same type of work is over $200. per hour but then again a mobile home cost over $300.000 so it's all relative.

Thanks again for your posts. I always enjoy reading them.

Nice job and very creative. Your customers are lucky to have you as a resource.

Thank you very much. I should send you my customers mailing list so you can mention that to them :laughing:

nice job excellent weld.and good business ethics.i noticed in another post you used miller 251 now 350 how to like it compared.looking to trade up from my 210 thanks.

The 251 was an excellent machine. I replaced it this year with the Millermatic 252 and Millermatic 350P. Nothing wrong with the machine. I just had an opportunity to upgrade and took it. The 252 and the now discontinued 251 are very similar machines but Miller states that the 252 has a better cold start than the 251 but I never noticed it.

The 350 Pis a whole different beast.Thanks for your post.