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Welding Aluminum Bracket for Ancient Dump Truck

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  • Welding Aluminum Bracket for Ancient Dump Truck

    During disassembly by mistake my customer broke off the ear of the bracket, because he didn't see the last bolt. After I cleaned up the casting I noticed that there was a second crack. I grooved out the 2nd crack from both sides for 100% penetration and filled it up with weld. When I was grinding the broken off ear, the carbide burr caught it and threw it from the vise, never to be found again, so I had to make a new one. Fortunately I had the welding and machining fixture done by that time, so I new where to locate it. The following pictures document my progress.

    1. Cracked Bracket
    2. Cracked in two places
    3. Outside of 2nd crack
    4. Inside of 2nd crack
    5. Making welding and machining fixture

    Click image for larger version

Name:	1. Cracked Bracket.jpg
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ID:	701139

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Name:	2. Cracked in two places.jpg
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ID:	701140

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Name:	3. Outside of 2nd crack.jpg
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Name:	4. Inside of 2nd crack.jpg
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ID:	701143
    sigpic
    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    Here are some more pictures:

    6. Bracket mounted to fixture
    7. Making new ear
    8. Carbide burr to bevel casting
    9. Standoff for welding ear
    10. Spotfacing excess weld

    Click image for larger version

Name:	6. Bracket mounted to fixture.jpg
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ID:	701145

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Name:	7. Making new ear.jpg
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ID:	701146

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Name:	8. Carbide burr to bevel casting.jpg
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ID:	701147

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Name:	9. Standoff for welding ear.jpg
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ID:	701148

    Click image for larger version

Name:	10. Spotfacing excess weld.jpg
Views:	39
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ID:	701149
    sigpic
    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

    Comment


    • #3
      Here are the rest of the pictures:
      I will try to get a picture of the truck when I drop off the repaired bracket.

      11. Bracket welded and machined
      12. Close up of welds

      Click image for larger version

Name:	11. Bracket welded and machined.jpg
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Size:	79.8 KB
ID:	701151

      Click image for larger version

Name:	12. Close up of welds.jpg
Views:	39
Size:	88.2 KB
ID:	701152
      sigpic
      Miller Thunderbolt
      Smith Oxyacetylene Torch
      Miller Dynasty 200DX
      Lincoln SP-250 MIG Welder
      Lincoln LE 31 MP
      Clausing/Coldchester 15" Lathe
      16" DuAll Saw
      15" Drill Press
      7" x 9" Swivel Head Horizontal Band Saw
      20 Ton Arbor Press
      Bridgeport

      Comment


      • #4
        Dimensions please!

        Comment


        • #5
          Click image for larger version

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Size:	69.8 KB
ID:	701182Click image for larger version

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ID:	701181
          M
          Originally posted by eatpraylove View Post
          Dimensions please!
          I used 3/8” screws in the holes.
          The attached picture gives you a sense of size.


          sigpic
          Miller Thunderbolt
          Smith Oxyacetylene Torch
          Miller Dynasty 200DX
          Lincoln SP-250 MIG Welder
          Lincoln LE 31 MP
          Clausing/Coldchester 15" Lathe
          16" DuAll Saw
          15" Drill Press
          7" x 9" Swivel Head Horizontal Band Saw
          20 Ton Arbor Press
          Bridgeport

          Comment

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