Repair a CRACKED Caterpillar 789 Dump Truck Suspension Part | Machining & Welding
In this video we are machining and welding to repair a cracked Caterpillar 789 Dump Truck suspension part. This part is the top cap of the suspension Front Strut on the dump truck. There is a crack right through the weld joint holding the pin into the top cap and the pin has been damaged. To repair we need to machine out the damaged weld and pin before drilling, boring and weld prep machining the top cap to suit the new pin. We machine up a new pin using 150mm (6” inch) 4140 solid bar and then interference fit into the top cap before MIG welding with Hobart Fabco XL525 dual shield wire. The suspension part is then back in the lathe to finish machining the weld and pin down to size. We then drill and tap a 1" (inch) hole in the pin to complete.
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Hey viewers thanks for watching todays video on repairing the cracked CAT 789 dump truck suspension part. That was our longest video yet! A few machinist porn shots there to enjoy 😂 let us know in the comments which part of the video you liked the best? These front strut parts are obsolete and hard to find 2nd hand so not much choice have to get it repaired. There was a full day in this job to get it all done 😎👍 Subscribe and hit the bell icon to turn on notifications so you don't miss our weekly uploads. 👇 🤳 Follow us online here: Instagram instagram.com/cutting_edge_engineering Facebook facebook.com/cuttingedgeengineeringaustralia/ Official CEE Merch shop: www.ceeshop.com.au
one big question each video: how long did it take in realtime each video... only the welding take take real long, 7-8h cool down
Hey mate yeah for the whole processes is a good days work
Love the work u do mate ...even with the asshole interruptions lol u gota love the outtakes lol the best part for me . .keep em coming please mate
I know it might be sensitive but I can't help but wonder what a job like this would cost.
@@joegee2815 8 hours X shop rate plus materials?
Do not ever worry about the length of your videos, I don’t care how long they are because I get to see more of the actual work and they are not so cut up
Agreed
And that’s a fact
More about the quality than the length... So I keep getting told... 😞
agreed
@@clint2169 different films bud
I love the white arrow pointing to the crack: "Mate, in case you are wondering - here's where it's fucked"
There was about 4 arrows drawn on there just to make sure I could see it 😂
heaven forbid they fix the wrong thing.
@@FishFind3000 No doubt that it happens.
@@markfryer9880 Bad enough when fixing a CAT hauling truck. Worse when it's a surgeon taking off the wrong leg.
😂😂😂
I am also a welder. I built and repaired mining equipment for 30 years. I sure miss my trade but to old and reduced to repairing stuff for homeowners and minor repairs to trailers and such. I really enjoy this channel because You are proud of your work and doing it right the first time. Thank you for your great craftsmanship.
Drilling the hole all the way through the new pin to relieve welding heat gas pressure said it all for me. This dude knows where he's been and how he's going to get to the end of the process at hand. Bravo Maestro. Stay safe.
I think that was to let the air out of the hub as the pin went down the hole.
It also prevents air heating up and blowing out his welds before the metal solidifies.
Question ? should that hole have been closed on completion?🤔
@@garydawson5928 Quite a small hole in a very thick piece of metal and enclosed on both ends, so it likely won't matter at all.
Never stop adding outtakes.
I agree the outakes are just gold.
@@MrFixiit just watch out for Askholes. ;) (36:29) (Did they see that? 😂)
Agreed
“That is six thousandths in bananas.” That is awesome. Lol.
I have to work in thou and I hate it cause I'm so used to metric lol
Thou is kind of half way. They are milliinches. The problem is that they're still inches.
Yeah, I can do that math in my head like that too.
@@masheroz Exactly. In electronic PCB layout they're using something called "mil". Which is the same as a thou. Not to be confused with a "mill" which is a millimeter.
LMAO!
A true tradesman, not only at the top of his game, but obviously has a true love and passion for what he does which ensures every job out the door is perfect and of quality. Values and workmanship hard to find these days. You guys do a great job and amazing videos 👌👍
There is no doubt that you guys are absolute legends. The level of knowledge in all your video’s is off the scale. Your missus has clearly either got training or unbelievable natural talent in production (getting audio and editing right for this type of stuff takes skill). I reckon a big part of your audience is people who are not professionals, if there was any way you could show costing of repair vs replacement part I think it would really help people appreciate the value of your work. You are an extremely talented and relatable couple. Keep smashing it!!
Hey mate thanks so much for this great comment and feedback! We both appreciate the support, the missus hasn't had any training but she has a passion for it loves doing this sort of stuff. Will see what we can do to add repair vs replacement we do often get asked about that. Cheers 😎👍
I don't know anything about any of this stuff, but I find myself fascinated by the process. Like the format: problem, proposed solution, steps to solve, occasional dog interaction, solution, giggling at outtakes. Thanks for making these. Your well explained approach makes this seem straight forward but your skills are off the charts.
Hey Lance thanks for watching mate and the feedback appreciate it! Cheers 😎👍
Many excellent machinists on KZhead, but most only make new tools for their own shop, and useless example pieces. It is a pleasure to see an excellent machinist that also does real work. You are a rare breed, and I hope your customers know how high the quality they get is. Would be interesting to see more of your business: Customers, Suppliers, neighborhood, &c.
Hey mate thanks for watching and the comment, yeah we wanted our YT channel to be about keeping it real. Cheers 😎👍
I think many of the youtuber machinist keep their real work out of tye videos
@@bastienpabiot3678 not Abom69. his videos are long, but he does Job Work too
Its poor form if you need to insult someone to give someone else a compliment.
@@Hyratel no he doesn’t - look at some of his older stuff it was big work now not so much
I am no mechanic or machinist and I have said it before you are an artist and I am just gobsmacked how you do these sorts of jobs so entertaining. The job ended up looking like a factory-made piece just amazing.
I used to buy work like this when I was a power station engineer. We used the people who could do the job properly. Central purchasing were kept out of it because they went to the cheapest and we paid the price of failed equipment.
The Hi-Res close up shots on the lathe are magnificent.
Hey mate my missus says THANK YOU! She actually got a new phone/camera and had to get used to it so glad someone noticed haha 😎👍
so your cameraperson is your missus... you still haven't introduced us... i do enjoy the background giggles, and she does a good job with the camera and editor too.
@@1verstapp The giggles are priceless. Kurtis is a very lucky man.
Might have to invest in a go-pro.
My missus is happy using the Samsung and iPhones for now. 😎👍
You should not worry about the length of the video, every bit is enjoyable - watching a master performing miracles. And every f**k is where I would say it too. Looking forward to every episode. Stay safe.
Hey Les thanks mate glad you enjoyed it! And my missus appreciates the feedback she wasn't sure if it would be too long
@@CuttingEdgeEngineering She is doing a good job, and love the outtakes and, of course, your puppy
The longer the better. 😝 (seriously though, good video)
I love it when it’s the time of day that whatever is in the lathe magically turns to copper.
Kurtis, as I'm sure many people have said, not only do I respect your knowledge and skills as a craftsman, but I also appreciate your willingness to include out takes. Not only are they human and humorous, it also reminds me to go easy on myself when I don't get it 'perfect' (a dangerous idea in itself) on the first (or 2nd, 3rd...) try. And thanks to Karen (if I heard your name correctly) for being a great videographer and producer. And thanks to your mascot for being a never-ending source of enthusiastic inspiration - on the first take, none the less! Cheers from a Yank.
"That's not a repair; THIS is a repair". I always learn from your videos. A few interesting things in this one.
hahaa thanks for watching mate!
I was thinking as well how politely he was saying, "This old repair was shit. Now let's do it right."
Too be honest, the fact it broke in the first place is an indication something is fishy here. Usually a part is never stronger than when it leaves the factory brand spanking new, and that broke soo...
I learned you can weld 4140 without preheat!
@@MrGofarkyself Me too😀
Interesting to see a Part that was forged at our company in germany getting repaired 😂
Was the repair good from manufacturer view point?
@from the dark side of the moon read your comment before you add it .
The forging looked good. Cant say I'm very impressed with the set up when it was finish machined. 1/8th of an inch TIR is a bit excessive.
hallo oliver ,echt jetzt?
@@jameslederer7613 It was a failed repair that developed all the runout which had no relation to the original forging.
I'm only here for the out takes lol. I enjoy watching your videos. Thank you.
Karen, you really do an AMAZING job with the videography and editing. The outtakes are gold, and your artistic videography keeps me looking for new episodes every week. Thank you both!!
Love your work mate! Could watch it for hours, it’s funny come home from work “boily fitter machinist” and watch more work I’m loosing it!! 😂👍🏻
Hahaa you got it bad mate! I do the same, free time spent watching other machinists on KZhead 🤣👍
40 years ago I learned the profession of lathe operator and I am always happy to watch you at work! The best way to relax after work 😉👍 Greetings from Germany and have a nice weekend
Awesome mate thanks for watching from there 😎👍
Measuring too tite
So glad found an episode I have not seen yet. Needed to relax tonight !!!
I'm watching this while 3d printing something so I maintain a perfect balance between subtractive and additive machining
There it is! Got my coffee already. Have a nice weekend, everybody!
Cheers mate enjoy your day!
@@CuttingEdgeEngineering you too! Awesome job btw, nice video
Got mine
Superb work mate.💪
Lots of whiskey for the weekend
This is like watching Abom back in the days when he still did "heavy metal" - this is a Good Thing. Thank you, I've learned a lot, liked and subscribed.
Hey mate thanks for watching and subscribing!
Yes I’m missing Abom79 doing the heavy stuff. But he can clock a part in a 4 jaw like no other. There seems to be a lot of reliance on the accuracy of the 3 jaw here. I’d have thought these parts would need to run very true. Non the less very proficient and watchable.
Thanks for watching mate. Our 3 jaw runs true no need to use a 4 jaw 😎👍
@@CuttingEdgeEngineering you do some big stuff and some of the best welding I’ve seen. First rate. I thought it rained a lot here in the UK but I’ve watched a few of your videos where’s it lagging it down!!! Great you both take the time to share the jobs you have through the workshop. Excellent
Great job! I swear that I can almost smell the cutting oil coming off the machine as you turn those parts! Awesome!
Seeing and hearing how robust and versatile the button inserts are, has really opened my eyes to better machining. I had thought one had to work only within the very specific strengths of each tool type. So cool, thanks Kurtis!
Ahhh. Brings back memories. Quite miss using a lathe.
I'm not the type of fella to ever do this kind of work, but I'll be damned if watching you don't make my OCD feel better. I absolutely love perfection, and you are an absolute provider brother. Love the doggo too. I'll watch as long as you upload
Hey Greg thanks for watching mate glad you enjoy the vids 😎👍
Done a lot of machining and welding repair, but this is just amazing. Great that you explained the processes. You the man bud!😎
I really enjoy your Vids. s a 35 year T&D man I greatly appreciate your work. knowledge and skills, and a special thanks goes to your saintly wife and your Wonder Dog
A buffing wheel is a perfect chew toy for a staffie! Brilliant!
Enjoyed the video a lot. My dad was a apprentice machinist during the Great Depression and worked his way up to shop foreman, then shop manager at a steel fabrication company. They built railcars, bridge structures, bearings, etc. I don't think there was anything he couldn't look at and get it fixed. I loved being in the shop with him. People don't realize how much knowledge and training go into working with steel. My dad would be watching this video and telling me exactly what was going on. Very cool.
Discovering the cause of the failures you're repairing is really interesting. Finding the threads and crud under the first repair surprised me. Great videos regardless of length. Much appreciated, Cheers from Canada
Hey mate thanks for watching! Yeah that thread surprised me a bit too haha.
This guy is a welder, machinist. A true tradesman. I like your content. I am an Engineer.
So glad I found your channel. Brings back so many memories of when I had a workshop doing exactly the same sort of work you do. LOVED EVERY SECOND. Retired now but would love to get my hands back on the tools. Keep the vids coming.
Ad we thought that Stellite was the miracle answer! I migrated to the drawing office. I was made redundant and tried going back to the workshop: Just couldn't do it.
I absolutely love how the holes of the part are standing still in the video. The rotation speed of the lathe at the holes and the frame rate of the camera match. Very satisfying 😍!
he did that on purpose too.
The best thing on You Tube by far, love it love it love it, Homeless was never putting that disc down.
Not a chance!
Cheers mate! Thanks for saying so!
Need more videos of that doggo...
Kurtis is a master machinist.
I like watching the slow mo curl of that weld coming out
Like watching a rocket surgeon at work. I love the diagnosis, probable solution and execution. Your channel is so much more exciting and fun to watch now.
Hey mate thanks for watching and supporting we appreciate it
@@CuttingEdgeEngineering wewwaw
@@CuttingEdgeEngineering qwq
The best equipment repair/machining channel hands down!! If I was in Oz I'd be knocking down your door for a job, guys like you make us all look good, cheers Kurtis!
Hey Jim thanks very much mate! Appreciate such a great comment. Cheers, Kurtis 😎👍
Dude...the slo mo rocks! And so does Homey.
4140 for the new pin, nice.. the good stuff!
Love it, you sound like a bloke who has just had enough of dodgy crap. Same as me. Nice work. Love watching how you do it mate.
Hey mate thanks for watching. Yeah that and I'm not one to beat around the bush will tell it how it is 🤣👍
So true but at the same time Kurtis keeps the coin rolling in fixing f-ups.
31:32 the old tenth of a thou whistle 👌
Very nice 👌👌👌
Apart from sharing with us your amazing skills, the camera work is fantastic, 10/10 on capturing it perfectly.! And love the out takes!
Greetings from Greece! Thank you for all of your videos, I'm a mechanical engineer student and your videos are the best way to see a lathe in full action due to covid we can't go to any workshop lessons and videos are the only way to see how these machines work . Once again thank you!
Hey mate thanks for watching hope things get better for you all over there!
9:20 - that was definitely a drill bit! I thought you would've finished with a nice coat of yellow paint. Kurtis - that was wildly impressive from go to whoa. Thanks so much for sharing. Most guys find it pretty damn incredible to see an engineer/machinist at work. Really enjoyed the whole process. Hell of a weld you used to attach that pin! Cheers mate.
Hey mate thanks for watching glad you enjoyed it! Yeah would've given it a coat of jam at the end but this customer has their own assembly/paint shop and they prefer to do all that before it goes on the machine. Cheers, Kurtis 😎👍
@@CuttingEdgeEngineering couldn't you have bored right through that disc and then welded the pin in a V on the other side?
@@jimmycricket5366 That is a very bad idea... it would break off in no time.
What a brilliant tradesman he must have been a superb apprentice the man or company that tought him have taught him the right way
That XL525 is a good part of why it never fails. Aside the great machining and the good ol know-how of course.
I love how their are so many different jobs that you can apply welding too
A big "Well Done" to Mrs Cutting Edge, the camera work and editing is always spot on!!!
4:20 the stroboscopic effect is just awesome
These videos are awesome. If they had been available in the 1960's they would have blown peoples minds, and made me into a wizard.
I love every single video you guys put out. I learn a lot of different ways to tackle a problem by watching skilled craftsman like you Curtis. Thanks to you and your wife for entertaining and teaching.
Crikey! Kurtis! Big tools, big chips. Love the music they make when they are peeled off the work! I have channel addiction- and I won't stop!
Hahaaa nice one mate! There's no such thing as too much machining 😂👍
I'm a bushman by trade, cut trees, fleeted native logs with bullies, firebreaked, fought wild fires, and shot pretty much what there is in NZ bush, but I've never worked indoors let alone seen what you do here with your video's. Thanks for shearing and keep them coming I find them fascinating, another mans world.
You downloaded a new video today and now I have to go through and watch a bunch of older ones geeze.. 😁
Your channel really is some of the best entertainment around, congratulations. Best bit , the pin drop in
That was pretty sexy, and oh so satisfying!
hey mate thanks for saying so we appreciate it! Yeah that was satisfying!
Is your videographer also a machinist because she knows all the right positions to capture the action. Love her giggle and of course at your expense but oh well, I'm sure she loves you.
She knows how to stop and start the machine hahaa just intuitive after watching me work for a few years 😎👍
This sure brings back memories of machine shop in high school in the 60s in England, not that we did anything as complex as what is shown here. We had lathes, mills, drills, bandsaws, aluminum casting, welding, brazing, etc. I made a drill vice that is still being used today by my brother. All such learning was thrown out in favor of computers. I was a software engineer for 48 years and machine shop and technical drawing were the basis for my SW skills because it was all problem solving.
I have never seen someone as dedicated as you are to making sure the job is done absolutely right. I've enjoyed every video. Thank You
that is why customers come back alot of shops don't realize this
That was my first video from you and I couldn't stop watching. I was a trained welder and always wanted to learn the rest of the stuff. It's amazing what you do
Hey mate welcome to the channel glad you enjoyed the video 😎👍
There was a time when engineers always rebuilt these machines, it is a fascinating process to watch, full credit to you guys for bringing it back with these great videos.
Some huge companies will toss stuff in the trash because of the potential liabilities if they repair it and someone gets hurt using it. I've seen some stuff chucked out that was amazing to me, a cheapskate.
I’m surprised this extremely important pin is so small.
Молодец я тоже на все руки от скуки и горжусь такими людьми как Вы жаль что не в России привет из Хабаровска на реке Амур
Hello from 'Merica. I welded tons of large tubing and pipe as a kid. I could weld all day and not ever tire of it. I could do that work everyday for the rest of my life. Watching the machining and welding of sold mass steel get me wet!!! :) P.S. excellent job on the video and the dog training.
Как же Ахрененно всё же смотреть как другие работают и выполняют свою работу на 100 балов из 100 👍👍👍
99,99. Не покрасил((
Hmm it's 2:15am I should probably go to bed soon... I wonder what's on youtube... Oh I guess I'm not going to bed till 3 🤣
😂👍 sorry my missus made this extra long
@@CuttingEdgeEngineering DON'T BE!!!!!!
@@CuttingEdgeEngineering don't be sorry mate, this is some really interesting stuff you're showing us
We love every minute. Always stay for the outtakes.
@@assassinlexx1993 ^^^ what he said
Don't ya just love this guy, I bet he's saved his customers collectively, totting it all up millions of $dollars, on what they would have had to spend on new equipment. I skip odd bits but a good 1/2 hr coffee break.
Only just started watching your videos; more entertaining that watching films these days. This video in particular takes my back to my heavy engineering days as an apprentice. We did not have the luxury of TIG only stick welding and hand operated turning devices. All the machine tools were marked 'WAR FINISH' but we managed. I remember an old timer telling me, "Your in the jungle now boy", lol. Keep up the good work. UK S. Wales.
4:46 Trippy! The framerate matches the lathe RPM.
the shutter speed with that RPM is great with how those bolt holes look.
Thanks for watching mate
Good thing our vision doesn't see in 30 frames per second. People would be trying to stick their fingers in there!😂
I haven't been a fan of anybody since 50years - this changed since I've seen this channel. This is so great work, thank you for sharing with us!
Hands down, engineering, greetings from Egypt
From busted and crusty to a work of art! Thanks for posting!
Glad you enjoyed it 😎👍
Woohoo, it's Friday and a CEE video. Great to see some lathe work. Nice job.
Thanks for watching mate!
I really enjoyed multiple parts of the vid - use of button inserts, the exploration of the previous work, the preparation for your own welding.
Wow. 12:22am. Spinning around and around an around 🤪 lol Awesome work brothers🤙🏼
It ended up looking like a delicious piece of caramel candy! So perfect mate!
Thanks mate!
Now we need to know who “The Askhole” is. Great videos, they’re never too long.
hahaaa we know a few of our customers and friends watch this so will keep them guessing 🤣
@@CuttingEdgeEngineering Chances are if they're asking if they're the Askhole, the answer is a resounding YES!!!! I should know, I'm occasionally one of them... But only when I'm REALLY trying to Piss someone Off...
i'm 27 years old and i'm a lathe turner on a new machine Weiler E50 lathe it's basicly a manual NC - or small batch programs CNC like yours. I'm enjoying this content alot cause it's basicly what i do daily like you but on the other part of the world and also alot of parts you make i recognize on daily basis here aswell ;) and even tho i got some experience in this job (started at 19 years old) you just never stop learning new things :D Awesome channel.
that slo mo is very satisfying to watch
I’m going to need to get myself some button inserts and tool holder after seeing this. They can really hog material.
Yeah mate can really feed them, great time savers. 😎👍
I’m sure you’re busy as hell, thanks for bringing us along!
Welcome mate! Yeah pretty flat shit hahaa
Now there is a dude worth his weight in gold. Absolutely facinating!
I hope he has a apprentice some day so that he can pass down his knowledge,the attention to detail and variety of skills he has is second to none
I come to watch the machining content but stay for the dog clips and the outtakes. You guys put out great videos. Hello from northern Illinois USA.
Hey mate glad you enjoy the content thanks for watching mate
Absolute legend. Love the channel and the out takes are total gold.
Hey cheers mate! Thanks for watching
That Homeless is a smart and well-trained canine. Love the pup.
a movie star .. oh , nice job on the pin ...
You are a machine artist - Such precision with such heavy components. Such great insight into this world.
Plus a super-dry sense of humor. I loled when he said "about 6 thou in bananas".
Beautiful workmanship and attention to detail. It's a pleasure to watch a skilled craftsman who takes such pride in his work. Even if you charged the customer triple what they paid, they still got a helluva bargain.
Hey Steve thanks for watching and commenting mate 😎👍
1.41 in that eye twitch caught me off guard haha keep up the good work and give the safety officer a pat for me
Watching great skill at work is quite hypnotic!
The pick of the KZhead Pics. Great job always good to watch.
Cheers mate! Thanks for watching
Outstanding Karen and Kurtis...Cheers
Hey thanks for always being one of the first to comment!
Man, I am enjoying your videos. I am retired since 2017. I am not a tradesman but I enjoy the work & appreciate the skills. Thanks for sharing.
The more i watch your videos the more i miss working on manual lathe