Welded Hydraulic Cylinder That Can't Be Repaired, Cut Open and Resealed

[Music] hello welcome to topper machine i'm josh topper so today's job is to service an unserviceable hydraulic cylinder and what we're going to wind up doing is cutting the the back end of it off and then taking it all apart repacking it and then welding the end back on now this cylinder comes in from a customer of mine that's uh actually a hydraulic shop i'm doing all their machining and this is one of those that their customer is desperately in need of so we're gonna do what it takes to get this job done for them and get them back in business okay so the first part we're gonna do on this job is we need to cut this end cap off but i don't know how thick it is that's where this comes in this is an ultrasonic thickness gauge and i use this for boiler testing to test for thickness on boilers but also for other things in the shop here and we'll go ahead and calibrate it and make sure i got my cup went a little bit there and touch it to the end cap and 385 so we're about 3 8 of an inch 382 depends on where i wiggle it to 377 so it's a 3 8 inch cap there should be a little step here that goes inside the tube just a little bit and then it's a chamfer that's welded so i'm going to shoot for cutting in probably a little less than the 3 8 and try to hit that and get that to pop off but so one more thing on this cylinder before we throw it up in the lathe that's absolutely critical is the port for the line is on one side and the eye is on the other so it's offset so we need to make sure this thing is timed right when put back together so i'm gonna put some center punch marks on the cap and on the barrel just to give me an alignment when i put it back together [Applause] [Applause] okay so the first thing i'm going to do here is i'm going to take a nice little skim cut just to clean up that weld so that it isn't so hard um start using my parting tool on i'm running 500 rpm [Applause] [Laughter] the hell so that's about the weirdest thing i've ever seen i had that little knock in there it was weird and i took it out of the chuck it's not there so it must be in the cylinder because there's nothing that was hitting i don't know i've never had anything like that so just go ahead and put it back in and try it again there it is that is so weird so something internal of the cylinder is making that knock i don't know how well you could hear that i'll see if i can move the microphone in better but we'll try that again it sounds like there's something this cylinder is just totally messed up maybe that piston slapping inside of there i i don't know it's weird but i guess i'll slow it down some and and we'll just do the work much slower so we don't do any damage to the bore still not great but we'll just take it easy and see what happens and that really is weird i don't know what that could be but we know this cylinder is bad so got to take it apart anyway all right so i got turned in a little bit now i'm going to take my round button insert and just start cutting in and and working it slowly just to see where we can how far we can go i don't know what the cylinder wall thickness is i don't know what the bore is there's no specs on this cylinder so it'll be a learning experience all around so before anybody can ask why don't you use your fancy ultrasound on that and see how thick that wall is well it doesn't work the best on these round surfaces um but you know what let's give it a try i'll have to clean the paint off in a spot to get good con you know penetration you gotta you can't have paint or anything to get a good reading on the wall but let's give it a shot [Music] okay so i got my spot cleaned up here let me get the ultrasound up there so you can see it there's my calibrated thickness off of the little test spot right down here and touch the probe oh it's getting signal 268 is the wall thickness that's cool so this little symbol down here shows me the wall thickness and as i move it around it changes a little bit see if i can get anything down here and no it's surface is too rough in here to get a reading so but that's a good good thickness so we'll go we know how to go far to go now so let's get started all right so i'm just going to start right here boy that's obnoxious and we're just going to go in slowly and easily and just see what we can do [Applause] because i don't want to go [Applause] too far and make a mess [Applause] but i just want to separate that head in fact let me touch off on the barrel here zero my breed out we're just gonna work it [Applause] [Applause] [Applause] [Applause] and we're close let me just take a quick look and see what we got where we're at and double check that i didn't take off my punch marks that would be bad no they're still there looks like i got a little ways to go yet so i'm going to switch over to a parting tool now because i have a decent groove for for uh filling with weld and then i'll just try to part it the rest of the way and hopefully we don't screw up too bad so i got my parting tool in there and i know like i said that head thickness is 3 8 so i'll just get close to the end zero my indicator oh my readout of course i didn't hit the right one yeah i think i'm going to start back here just so i'm not going in that full 3 8 of an inch let's just see what happens [Applause] sorry about that battery died on me so i'm real close i'm almost to my depth i don't want to go too far and run the risk of not being able to get this back on well [Applause] i think we're there there it is just like that and i shouldn't have too much problem welding that back on i see they just butted it up to the end of the tube they didn't even put a step in it so let's go ahead and get this thing out of here and and get that get that piston out of there see if we can figure out what was knocking in there that was i said just just weird all right so i got it over here in the vise let's see if we can pop this thing out of here and there it goes [Music] there ain't even a seal on there so that was the piston hammering in there [Music] boy this thing's weird okay to say the least that i'm confused as to what's going on here with this thing is just beyond me um there's no piston cup there's no seal there it's just a loose fitting plate and there's our end cap but we do know those seals are bad but it's just odd there should be seals here or something i've never seen anything like this but that's okay well i'll talk to the customer that's rebuilding it for me i'm just doing the machine work and we'll get the seals and everything kind of figured out and then we'll put it back together so here obviously is a failed seal and that one will come out nice and easy but that thing is just trash and then we've got the seal down inside there this one and see which one of my picks will work to get that out of there it's um be a stubborn one uh well i'm going to keep working on this off camera just so i don't bore you guys with struggles to get this out or maybe i'll do a high speed ha got it that little sucker did not want to come out but there are part numbers there so we should be able to get seals perfect so here are our new seals and so i'll go ahead and i'll get these popped in and then we'll finish assembling the cylinder huh all right now i'm just going to put a little grease on our rod here just to help it slip by on the seal [Music] i'll just give this thing a shove and it might go right in there it goes just like that so we're back here in the weld shop i got it set up on my roller positioners there are punch marks there and there they are there and since this thing obviously wasn't uh super precision we're just gonna butt it up there and i'm gonna tack it tack it in one more spot so when i built my powered roller stands a while back um and did the video of it they worked great absolutely love it except for on the lighter stuff when you get lighter things you won't run into problems i would have to get this ground to stay right here uh well see it won't stay ver horizontal out but it doesn't have enough traction to pull it around so we'll just weld these up on the bench and go from there [Music] [Applause] so since i had to do this in a few passes i'll hit it with the flap wheel clean it up make it look nice double check everything and then we'll go ahead and um you know get it ready and get it back to the customer they can pressure test it and then it'll be on to their customer to go back into service well there it is all serviced ready to go just because they say it's unserviceable doesn't mean that it really is you just got to get creative sometimes this will go back to my customer they'll pressure check it make sure it's all good and functioning and then it'll go back to their customer and go back into service so like i said you just got to get creative and uh also guys please check out my store frontier accounts the link is in the description below there's shirts and and a can koozie and some some things like that that i've designed up for you i hope you enjoy it and and wear it with pride and until next time get out in your shop and get it done right the first time [Music]

Channel: Topper Machine LLC.

Views: 71,940

Keywords: manual machinist, machine shop, topper machine, metal planer, metal shaper, sawmill, shop built sawmill, DIY, homemade, monarch lathe, Bridgeport milling machine, lathe work, boring mill, HBM, drill press, metal lathe, milling machine, welding, press brake, hydraulic repair, weld, unservicable, impossible repair, heavy equipment, tough repair, unserviceable

Id: iy9GTAuLTVI

Length: 21min 30sec (1290 seconds)

Published: Fri Aug 05 2022