Sugar Cane Mill Restoration: Welding up and Turning the Shafts on the Large Rollers

foreign ERS machinery.org guys uh back working again on these cane Mills that I'm working on a store and I got a Golden's number one and the Golden's number two uh that we're working on rebuilding previously we took the small rollers out of both of those Mills and we were able to get the journals machined uh freshened up nice polished journals I had to turn them down a little bit each one uh nothing didn't have to remove a whole lot of material the large rollers out of those same two Mills so we got a little bit more issue particularly with one of them both of them have got a fair amount of pitting on the shafts that we need to turn now now um you know the one out of the smaller Mill the number one meal I could probably clean it up without doing any kind of welding or anything but there's enough in there I think I'm going to weld up some of those uh and then turn them back down it'll just get a little bit of material in there the rollers are cast iron the shafts are steel to go through these so these are weldable and I have done that before you can basically just build it up and then turn it back down and have a really nice surface to to work with and not have to remove too much metal now the one office number two Mill there is a significant amount of pitting on this one of them here on this bottom end there's a little bit up in the top the top again we could probably turn out but as long as we're welding them up I'm probably going to weld up a couple of areas up here as well let me zoom in here and kind of show you what we're dealing with and we'll get started on trying to get these journals all fixed up and ready for some new Babbitt bearings so this one right here is by far the worst one and you can see I mean goodness gracious that's probably that's close to a quarter inch deep that pitting in there where some water just got on this shaft and and probably set down in that bearing cup in the bottom of the mill and over years and years and years the rust did its magic and uh did a lot of damage the good news is is that we've still got plenty of good material in here when they sandblasted it out they pretty much got all the rust out and yeah because this is still we can we can weld it up and we can fix this I've done it many times before so my game plan is is I'm going to come in here with a grinder and just kind of grind out these areas that need to be welded up I just like to get to some good fresh material make sure I've got all the rust out of there we'll weld it up a little bit larger than what it needs to be and then we can go to the lathe and turn it down to its final size this one here not bad there's a little bit of pitting in here honestly I could probably get by without doing anything to it but uh at least 10 here in the bottom I think I might weld it up just a little bit and up on the tops of the shafts you guys can't see it again I could probably deal with both of those there's a couple places where there's some pitting that I'll probably just go ahead and weld up and uh so I don't have to take too much material off of those Let's uh get these over here and start doing some grinding and get them welded up I think I got this set up to do some welding over here notice I got it up on some rollers this is going to allow me to just kind of roll this around while I'm welding um I've also got most of that old stuff ground out I'm down to base material all the way through this thing so I should get a good weld so now I just need to get dressed for welding and get set up for welding over here and we'll start seeing we can put some put some beads in there I think we're ready to weld this so again I've got my this drum on rollers where I can kind of roll it around and weld it up I got one area here that's really low but I'm going to pretty much build up this whole surface we're just going to use the MIG welder I've got a Lincoln Electric Power big 210 MP back here a little wire feed welder and that's what we're going to be using to weld this up note that I've got a piece of copper here just kind of just strapped over the back that's my ground as I turn this it just kind of rotates on there no big deal at all there so I think between everything this hopefully should go smooth so we're getting here and build this up let me get my welding hood on and we'll start welding I'm just trying to get a feel for how we're going to be doing this I can control the drum with one hand here and I can kind of direct my wand here with the other I think we're ready to go foreign to kind of build up the lowest areas first and I'm just going to basically go from the back and work my way all the way down and just put a whole new layer over this whole thing a little area in here needs to be built up I'm just going to start back here in the back I'm just going to make a big spiral and just kind of work my way to the front [Music] thank you all right guys I think we are done we've got that whole thing welded up we're going to let this cool down nice and slow now and uh that should be able to turn that out and get a good uh shaft down there I need to do the other side over here I think I'm going to let this cool down a little bit first there is a little bit of pitting on this side I want to take care of as well not near as bad as this side though that was by far the worst side just taking a closer look at it um you know guys I'm a machinist not a welder I can weld things together I can make things stick but my welds aren't the prettiest in the world and I'm not going to sit here and tell you they are but the beautiful thing about this job is we're going to machine all that off all we're trying to do is add material back to this part and get it all turned off smooth so it's not going to matter at the end of the day and as long as I don't have any voids or any pockets in that weld we should be good so I think it's going to be fine if we have to we can always go back after we turn it down a little bit if there's some voids in there we can weld those up and then finish this thing out I've got the part turned around now there's a bearing that goes from about here to here and there is some pitting in here it's not terrible I probably could turn it out but I'm going to go ahead and build it up and I'm not going to build up the whole shaft I'm just going to build up from about down here to about here I did kind of go in there and grind that area out and just make sure I've got plenty of metal there and we end up with a nice uh nice uh machine surface when we're through so we're going to go ahead and do this process here foreign this welded up as well again very little needed to be on there but that should have been more than enough to get this side uh trued up we're just going to set this roller over there I'm probably going to wrap it up in a blanket and let it cool down nice and slow and we'll be ready to machine it once it gets cooled down probably tomorrow we got all of our bosses welded up here we're ready to go to the lathe now before I do I'm going to go here in here and clean up these uh centers on the shaft so that we can properly set these up on the lathe so again just got a center drill here like you would use on the lathe same thing to drilled these originally we're just going to clean these up they're full of rust Gunk grease you name it and I just want to freshen them up here a little bit with the hand drill and that's all that one needs see all the gunk coming out turn these around do the other side there we go those look good let's get these uh set up over in the lathe I think we will check them up with a small end out first get that trued up and then we'll flip it around and get this side trued up and we just want to get a good bearing surface is what we're going for over here on the lathe I got this set up over here in the lathe again we're just chucked up onto the main cat or shaft up here that has not been welded on it is a little bit rough and Rusty but it's going to be fine this uh this this wheel is anything but a Precision running device this this uh these cane Mills run extremely slow RPMs think about a mule walking around in a circle how many times it can walk around a circle in one minute and you know you're probably only talking five or six RPM so you know and you just got rollers going again since it's just crushing crank cane in between it so keep that in mind and I will just go ahead you know you turn this thing on it's interesting the top part of this drum is running fairly true the bottom end down there has got a fair amount of run out in it I'm not too worried about that again that the speeds that this thing is running and the way it's being used is just really not going to matter and this is a casting that has been pressed up onto these shafts most of these drums like this that uh that I turn are not running perfectly true I've never really been that concerned about it so but what we do want to do is get these shafts cleaned up and running uh you know where we have good bearing surface all this weld that we put on here are almost all this weld is going to be turned off we were just basically building up a little bit of material to fill in some of the little gaps in there so let's go ahead and get the cutter over here and we'll start turning this thing out we're ready to start turning this I'm just going to try to come in here and kind of find the high spots right and we'll start turning it's just gonna be roughing right now until we get a fairly consistent cut around it just removing that rough weld like I said this is going to be really rough turning until we kind of get the hot spots knocked down and start making a fairly uh constant cut around there I am because it's an interrupted cut I'm only taking about 60 thousandths per pass right now 60 000 off the diameter so really a thirty thousandths cut once we get kind of below this uh the the high spots we can probably start taking a little bit more metal off but this is a rather rough cut right now let's take a quick look at it I know we're getting lots of chatter on that right now but again I'm just trying to get this rough turned and uh it's slowly cutting through we'll continue on foreign guys we are down here to the very end I'm just going to take a real light cleanup pass on this this should be the last pass appears to have cleaned up pretty darn nice we've got all the weld marks out really have not had the big chatter problem here toward the end which is good we're going to turn this out and I'm going to get some memory cloth and polish that journal I think we'll be about ready I do need to Champ for the bottom of that to clean up that rough Edge on it do that first and then then polish it let's see just about the end of our cut here I'm going to back my cutter out so I don't drag back across it let's just look and see what we got and I'm happy with that that looks good you can kind of see there's just a couple little spots in there I'm not going to worry about trying to turn it out it'll be below the bearing surface but um that's going to be just fine let me uh get a chamfering bit in here all right that's good some memory and polish it out and I'm happy with the results we will uh let that go I mean just a little one little Edge right there I'm gonna reach in there with the cutter and just face that off I think if I can get in there with it so I'm gonna use a different cutter that I can reach in there a little bit better with hopefully just trying to face out that looks good all right this side is done we will uh flip it around I'll Chuck up on this end we just turned and we'll get the the shaft on the other side turned out as well just flipped around now the side that we just turned is in the Chuck and I have some brass shims in here just to kind of protect it so we're not gouging it out and we're gonna go ahead and get this side turned down I did switch to a little bit different cutter I'm going to see how this one works the other one was working fine but uh just trying just playing around with anything else so we'll go ahead start rough turning that again and all I want to do is just get this cleaned up to to the point where we don't have any little holidays in there got good metal all the way around and basically just get it down as close to this original diameter as we can may have to go a little bit deeper all right let's do it I can already tell that's kind of the hot spot right there all right we are working this thing down I'm taking about 60 thousands per pass and uh this pass here probably not going to totally clean it up but we're getting down close to the original uh rough diameter there we've probably got another couple of passes still left to go here maybe not at the full sixty thousands but uh we are getting closer here I'm going to take a look at it after this pass and just uh see how things are cleaning up but I think we're getting down pretty close yeah we're getting real close here I'm gonna go ahead we're going to turn this whole shaft down a little bit and try to get that last little bit out there all right that last pass looks like it cleaned it up pretty good we're gonna get in here with some Emery now and just do a little polishing on this shaft uh get that bearing surface already so uh I'm just going to try to get this real nice and smooth for a Babbitt bearing to be poured on because that gear fits down here on the top of this I decided not to turn it down anymore down there just because I don't want to change the diameter of that area that fits up around the gear but uh this shaft is a little bit probably about 20 000 under size from what it was originally but that's just what it took to get it all cleaned up real nice and because we're pouring a Babbitt bearing on this the size really isn't critical because we're going to pour the Babbitt to fit the shaft you know it just kind of is whatever it is it's not like we gotta get it to an exact size for a ball bearing or something like that to fit up on so this should be just fine so we'll get this polished out and we'll have this roller done we'll need to do the uh second roller for the smaller Mill and uh probably just do that off camera some of the exact same process that we just did here I'm going to polish that a little bit more there's a little bit of chatter in there when we were turning that but uh we'll polish that out there we go all uh turned polished ready for about bearings so uh we got the two big rollers done plus the small rollers were done in a previous episode so these are all ready for rabbit pouring so hopefully coming up here real quick we'll get the Babbitt done on these and be able to get those cane Mills put back together and ready to squeeze some cane juice for this Falls uh cane season and that's the game plan so there you go guys that is going to be a wrap as always thank you so much for watching please subscribe to the channel if 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Channel: Keith Rucker - VintageMachinery.org

Views: 49,811

Keywords: machine shop, machinist, lathe, restoration, vintage machinery, woodworking, metalworking, how to run a lathe, keith rucker, vintagemachinery.org, cane mill, goldens foundry, sugar cane mill, cane mill restoration, goldens cane mill, cane syrup, roller repair, sugar cane press, vintage machinery keith rucker, metal lathe, goldens foundry and machine

Id: FW7CIxzYMyU

Length: 21min 33sec (1293 seconds)

Published: Fri Oct 14 2022