Making the Piston & Reassembly! | Hitachi ZX470 Cylinder Rebuild | Part 3
The Hitachi ZX470 Cylinder rebuild is complete! This video is Part 3 of rebuilding a stick (dipper arm) cylinder off a Hitachi ZX470 excavator. In this video we show the complete process of making a new hydraulic cylinder piston including modifying with a silicon bronze weld layer before reassembling the cylinder. We also show pressing in the new bushings with our 150-tonne hydraulic press, installing the new seal kit and painting the rebuilt cylinder. We hope you enjoyed watching the videos on how we complete a hydraulic cylinder rebuild!
MISSED PART 1?! Watch it here: • It's STUCK! Can We Get...
MISSED PART 2?! Watch it here: • Making the NEW Cylinde...
In this video we are using:
- Hafco TM-26120G Centre Lathe
- MetalMaster HPM-150T Hydraulic press
- WIA 500i Weldmatic welder
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The Hitachi ZX470 cylinder rebuild is complete! Let us know in the comments what your favourite part of the rebuild was and if you missed watching Part 1 or 2 check those out here 😁👇 Watch Part 1: kzhead.info/sun/f76Ggrhlhnira4U/bejne.html Watch Part 2: kzhead.info/sun/nMuOgb2QsJGmi30/bejne.html Subscribe and hit the bell icon to turn on notifications so you don't miss our weekly uploads. 👇 🤳 📲Follow us online here: linktr.ee/CEEAUS 🛍Official CEE Merch shop: www.ceeshop.com.au 🎉Get Early Access & Ad Free videos in our Patreon community: www.patreon.com/cuttingedgeengineering
wonderful video tonight..... .have a wonderful weekend Kurtis, Karen and Homeless...... cheers from the other 'Sunshine State' Paul
Homeless ripping up parcels 🤣
Kurtis and Karen you two are amazing what you have done for Matty 👍
I think for me the intros into how a machine works is always cool to watch, such as when Kurtis shows us how the welder works. Thanks for the knowledge!!!
id have to say my favourite parts of this build was when you polished the rod and when you left to get you’re mate to torque your nut LOL. brought a tear to an old mans eye it did.
I've been watching every one, every minute, no skipping, for almost 3 years. These never get old. Still enjoy them immensely.
wow what a fantastic comment to read, we can't say how much we appreciate supporters like yourself that have been with us for so long!
@@CuttingEdgeEngineering I feel like I have only been doing this for the last few months. Whenever there seems to be nothing interesting to watch I delve into the back catalogue. There is at least once a week I will introduce something out of your workflow and make my job easier / the end result better. I borrowed the earplug trick from the boys in the paint yard a few years ago such a game changer during masking up jobs. Exemplary work as always!
I am the same nearly 53 minutes just melted away his retention stats must be off the chart!
Me too, I can't get enough!
No skipping required, brilliant editing. That's what makes cee stand out.
I am a 30 year Submarine veteran. Coffee was my life. But when I can hold a cup while watching your videos and it gets cold-the videos have just enraptured me.
Wow now that's a compliment right there thank you
Always neat to find another sub guy in the wild. Also, coffee is life and likewise mine went cold watching this work of art.
Didn’t get my second cup till noon because this video was so off the charts well done!
great words - which I would like to agree
Kurtis's depth of knowledge shows why his business is so successful. I love how Karen will go to so many different extremes to get us the best shot of the work.
Not just his depth of knowledge, but they both work very hard and have high standards.
@@firstmkb Extremely high standards and work ethics.
Homey is a gentle giant 😂 I love seeing him in your videos
The silicon bronze filled seal grooves looked amazing. That's a quality part and the customer will have an exchange process taking hours instead of days. What a brilliant service!
I can't believe how easy Curtis makes, producing a pision look.
Well, it is easy, just lots of steps...
I’m sure he’s made many of them over the years. I can’t remember when I started watching this channel. The KZhead Gods just put it on my list and I was hooked,just like the watchmaking videos.
He is a true professional in every sense of the word.
I am a mechanical engineer in Canada and for the last 43 years, I’ve lived and worked all over the world. I have had a lot of fun, learned a lot and done well financially, but I often think that I could have had just as much fun doing the kind of work that Kurtis does - and watching these superb videos confirms that.
Putting those silicon bronze shoulders on the walls of those grooves was not just genius, it was a work of art! Enjoyed every minute of the video, as always. That cylinder really does look brand new. Thanks to you both and greetings from the Boschek gang in Germany. Have a pleasant and peaceful weekend.
Hey Bruce, we'd love to send you a little something! Can you please send us your Name and Shipping Address to shop@cuttingedgeengineering.com.au Cheers mate!
I enjoyed the way he goes that extra mile with features like tthe Si Bronze shoulders that take it above and beyond an OE quality repair! Excellent craftsmanship!
Oh yes, another majestic bin chicken. That always cracks me up.
Homey is such a well-behaved dog, even when he gets a little rambunctious. That shot of the boring head coming through the inside of the piston was exceptional! Great video.
Reminded me instantly of the shots of a Tunnel Boring Machine making breakthrough.
I was going to make the exact same comments! 👍🏻👍🏻👍🏻👍🏻👍🏻👍🏻👍🏻@@johnmorriss5308
How cool is this? It's such a small modification, but it solves a potentially major issue. One thing that I really enjoy are these multi part rehab videos. I like the suspense and the level of detail.
cheers mate thanks for the feedback
it's a nontrivial amount of work that will pay dividends in longevity for the piston for sure
Karen that fade during the paint was "Chef's Kiss"... the fact that it isn't needed but adds SO MUCH depth to these videos is superb. I badly want to see the tool that tightened that nut.
Have a google of "hydraulic torque wrench (square drive or cassette)". through a series of calculations, you set the pressure to a specific value for the required torque figure. one hell of a piece of kit! until the reaction arm slips and sends the whole thing at a great rate of knots in a random direction hahaha
I love how Karen magically sandblasted those parts for you! It must be nice having a magician around in your shop. 😊Nicely done Karen!
I thought that thing too, but at the same time wanted to watch the parts get clean. That sense of satisfaction at watching something get instantly clean (a little piece at a time) is why my wife always volunteers to use our pressure washer on the house or sidewalk.
I'm reminded of Hand Tool Rescue every time I see a sand blaster now. The face slam against the glass speaks to me.
That shot of the massive boring bar, roughing out and coming through the other side of the piston was pure art.. Kurtis has all the big boy tools 😮
That's exactly what I was thinking!
You meen the spade drill?
@@raindeergames6104*mean*🙂
@@simonilett998 engrlish is hard😁
Well, as the saying goes, “the only difference between men and boys is the price of their toys”!
'These two are malfunctioning'... That done me in. Thank you Karen, you really have a cracking sense of humour. A great series of videos again guys, people will soon start to believe you are professionals or something. Have a great weekend. WOOF to Homie.
You should write "Upgraded by Cutting Edge Engineering" on it. The fact that you make it better than the manufacturer is amazing.
Its cool that not only the customer gets his piston back fixed to an OEM level, but that they can watch the entire job being done with such precision and care! Its almost like insurance, proof everything was correctly done. That in itself is worth its weight in gold! Cause you know the saying, the less you let a stranger or mechanic touch your car to fix or do maintenance on it the less problems it will have.. always have to know or have a trustworthy mechanic if you're going to allow someone else to work on it!
This cylinder is going into Kurtis' exchange fleet; the customer that originally owned it couldn't wait for them to rebuild it, so they bought a replacement cylinder and Kurtis bought this one to remanufacture.
Dang, that welded-on Bronze ridge upgrade is pure genius.. Hitachi! watch and learn
Why doesn't the OEM part have similar feature? Would it be too expensive to do in factory production?
The man from Hitachi, he say ????????
Gday Kurtis and Karen, this was an awesome series of videos, the modification to the piston is a brilliant idea and another bonus to rebuilding these cylinders is there’s minimal downtime for the customer, brilliant job as always and have a great weekend, cheers
Hey Matty, thanks for commenting that we forgot to mention about the fast turnaround time with an exchange component, definitely a bonus for the customer. Hope you're feeling alright today 😄👍
Hey Karen... loved the fade to Orange in the painting segment 😁 Awesome video as usual 👍🏻
I have to tell you, the thing that I appreciate most about Kurtis is his willingness to take the time and explain why he does or doesn’t do things a certain way I’ve been a machinist for over thirty years….I’ve spent twenty six of those years running my own company producing forging dies for automotive and oil & gas industry. Every time I watch a CEE episode, I learn something new…..always great work Kurtis!
Kurtis, that's a pretty slick idea to incorporate the 2 silicon bronze wear bands into the cylinder rod. I like how you improve upon factory original components. I used to do the very same sorts of things as an industrial machine technician. 👍
My curiosity begs the question if this was an original idea, a borrowed idea or a collaborative idea? Wherever it came from, it was a brilliant solution to very real problem.
@@cyrilhudak4568 Everything is new, well-forgotten old. Russian proverb (c)
It's a borrowed idea. John Deere/Hitachi and Case/Linkbelt both do it on a lot of their excavator cylinders but not on all of them. Cat doesn't do it on their pistons that have the same seal and wear ring arrangement. Really it shouldn't be an issue. The only time I have seen this particular failure on an excavator was when a customer bought a reman cylinder from a John Deere dealer. It was rebuilt with wear rings that were too thin of cross section and didn't stick up past the lands (don't know how they accomplished that).
I must say Karen your editing skills are nothing but amazing, camera work superb , Kurtis just keep doing what you do its the very best well done you two :)
Thanks so much Robert!
Oftentimes, ductile iron will be used for pistons, so if the wear bearings (which are on each side of the center seal) wear too much, the ductile iron won't gall the cylinder wall. The iron piston would still need replacing. But, with the brass welded on the steel piston, it becomes totally rebuildable. Just re-weld and turn it back down. It's pretty smart. 👍
You got some sweet shots on your processes! Awesome content. They should create a Grammy award for inspiring content.
Wow, thank you!
I was just thinking the same.
@@CuttingEdgeEngineeringhey Karen, I wonder how YOU would do, operating the lathe for the first time
Oscar?
More like an Oscar, but yeah.
The weld in the middle is above and beyond. What a true professional who is dedicated to his craft. Bravo, my man 👏👏👏
The shot at 5:36 was straight like from Stanley Kubrick movies. Amazing work!
GREAT work!! My whole family loves your channel! We could watch your bloopers for hours! If I was to try it my video would probably be around 58 minutes of total screw ups followed by possibly two minutes of decent work. Jimmie
I’m in a shop that regularly gets over 100° every day for 10 hours each day. Do you know of any such thing as a cool as in lightweight welding shirt ? And work boots comfortable for all day ? Any suggestions would be greatly appreciated!
That foam earplug trick is going to be very useful for painting things with threaded holes. Thanks, something learned every episode.
The growth and development of CEE has been impressive. This was an absolutely beautiful build. I suspect in 5 years time we’ll see a video along the lines of “Righto guys so todays job is to make a Cat 336 for our exchange fleet; we’re having issues getting them here in Australia and its cheaper to make one here than it is to ship one from overseas” ha!
😁😁😁😁
I volunteer on a retired US Navy battleship and i must say the hardware we commonly work with is comparable in size to that seen here! One of the few places on earth where this can be said.
Love these repair/re-build videos. The interludes with the birds and the dog are just the icing on the cake.
The video quality is excellent, but so is the AUDIO. The amount of time Karen puts into synchronizing the sounds of the time-lapsed cuts beginning and ending, the ASMR quality of Kurtis handling the swarf at the end... superb! Your efforts have not gone unnoticed!
Oh yes amazing!! We also hear someone rip a little one at 30:18. Love waching his vidéos 😊
"Video, and, so is the audio." Your grammar hurts my head 😅
As I watched Karen check the interior of the cylinder to see if the lady bug was still okay, I was relieved to know that I wasn’t the only one worried about every last one of the creatures on this planet.😂 Unbelievable quality repairs Curtis! Thank you both for the great videos.
If you had a stencil with the CEE logo to paint on finished part that would be the icing on the cake. Great job.
Looks very pro to me. I watched all 3 parts. This guy has the full knowledge and capability to deal with these large cylinders properly. Plus the dog & birds are fun! Well shot and edited.
It’s really interesting watching a craftsman improve an OEM part. I wonder if someone back at the manufacturer will take note. As with many, I’ve haven’t missed a video in years. And while I have no professional connection to machining, I’ve always loved learning about it. Great stuff as always!
probably not, if a part never fails you'll never need to buy a new one = no money to be made for hitachi selling replacement cylinders
Manufacturers care about brand value, and will sell more of a product if it has a reputation for durability. If this type of failure is unusually common, it may behoove a maker to update it's own equipment in order to derive more overall capitalization through goodwill than via replacement sales.@@dazasc3994
That shot from inside the lath as it breaks through is just brilliant.
Kurtis is definitely no.1 machinist on KZhead (at least in my opinion) . Gets on with the job, without talking b0llocks for half an hour 👌 whole repair process is well explained too And obviously, the quality of videos/ montage, courtesy of Karen 😉 job very well done
most of the others have no idea how to actually remove metal. It's so frustrating to watch them going so slow.
Honestly, I'm a long way from watching all the old videos. Trying to run them as you made them. Every once in a while I jump a video or 2 and realise I'm off somewhere🤔🤔😱😱
Here I am, in a horisontal position onto my sofa, watching someone fixing other people’s broken shit on the other side of this gigant clayball.... And enjoying every single second of it! 👍 Keep up the great work you are doing! Thank you for the videos Kurtis and Karen. Best wishes from Sweden! 🇸🇪
Not only did you refurbish that cylinder back to OEM standards but you actually improved on it with adding the silicone bronze. That piston looked like a piece of jewelry after you were done with machining it. Excellent video as well. You Karen and Homey produce top notch content that is absolutely enthralling. Who would’ve thought a finance guy like me would ever find your mastery of machining so appealing. Wish I was a younger so I could’ve perhaps considered it as a career. Doubt I would’ve been as good as you, but i would have a value library of videos to learn from! Keep up the great work and catch you on the next one.
bronzing to save damage, its simple, obvious, and nobody thought of it -brilliant
Great job machining, great job editing, thanks for sharing
Who would have thought that such a beautifull piece of machinery was inside that raw billet 😲 As ever, top notch filming and editing from Caren and of course expert craftsmanshipp from Curtis, pleasure to watch.
*Karen & *Kurtis
It's like 4am in Toronto and I couldn't sleep and came across videos 1 & 2 earlier. This is beyond my area expertise but find this so fascinating not to mention I'm very impressed by the skills, knowledge and experience. I'm also a sucker for a happy dog. lol
Every post is a trip down memory lane my friends.The bronze makes a great improvement to the inner workings of this big beast. You sure know how much I love big eh. The bigger the better for this old/retired chip maker. Well folks it is a thing of beauty indeed. Hope to see you soon my southern friends.
Hey mate, we'd love to send you a little something! Can you please email us your Name + Shipping Address to shop@cuttingedgeengineering.com.au. Cheers mate!
The one thing I love the most about this channel is that this is actual production machining. If there's a way to save time and still do the same quality, then Curtis is going to do it because time is money. There's no shortcuts, but there is production time saving. It really sets the pace for how I make signs also.
The amount of Knowledge that kurtis has is crazy knowing how to do all the things he does is one hell of a gift!!!! I enjoy soaking up some of that know how keep up the kick ass videos !!!!👍👍🤟🤟🤘🤘🤙🤙
True craftsmanship -- that new piston looked like a work of art!
I totally understand the color choice, but I can't be the only one wishing that cylinder came out in CEE blue. BTW Karen, that hyperlapse effect on the facing of the piston along with impossibly good audio crossfade was AMAZING. Being a customer of yours must be heaven. "Yea, we have this rebuilt cylinder here with specially made silicon bronze piston shoulders to prevent wear damage." Love checking in with you two every Friday.
Another fantastic project done. The more I watch this channel the more I appreciate what Kurtis and Karen are doing. What are the birds that Kurtis feeds all the time.
They're Pied butcherbirds (Cracticus nigrogularis).
I can't imagine not watching these videos. We all know you're an artist with metal and technology associated with your industry, but now you're just showing off with the brush! 🤣🤣🤣 Another great series, Kurtis, Thanks to the whole team!
Excellent watch, as always. Kurtis engineering skills, Karen with the filming and editing, the human touch with Homie and the birds and the patience whilst Kurtis tries to work out what he is going to say. Way to go guys!!!
I don't know whether you're just bloody legendary at what you do or that your lovely missus makes you look good! 😂 Bloody great work as usual you two !!🤜🤛
Ear plugs in the bolt holes to keep the paint out. Excellent idea.
I don't know whether anyone else appreciates it, but I find the bird bits fascinating. It's remarkable how intelligent they are.
Karen’s camera angles and editing are world class excellent.
Hey Cutrtis, just found your channel and totally digging it! I'm a landscaper down in Moruya South Coast NSW where the Syd Harbour bridge stone-work was quarried and faced back in the 30's ... there's an open air shed/museum in town with a gigantic lathe for milling down granite colums etc. Has been talk in town for years about possibly putting it back into service somehow ...your 32 tonne milling machine install vid has put a lot of things into perspective. Totally unreal👍
hey mate welcome to the channel always great to have Aussie support. That must be a beast of a lathe! 💪
Never knew that of moruya, been there many times whilst fishing on that part of the coast
There's a little monument to the OHS casualties ... it's a lathe but also a facing mill as a big old cracked circular millstone is there also. Interested in knowing if anyone knows what sort of bit would cut granite? @@johngibson3837
We just need to clear our heads with your delightful casts... You are a breath of fresh air....
That earplug trick was like a lightbulb going off in my head. Brilliant.
Yep, I've not seen that before and, like you, that's got a permanent 'Simple & Clever' flag on it.
The rebuild was like the ingredients of a cake, with paint being the icing on top. No one favorite part, but as a whole thing is epic! Thank you for sharing it with us.
That piston is a sheer work of art! A great series of videos on the cylinder rebuild. 👏👏👏
I can appreciate having the right tool, the right tool diameter, the right welder, and the right machine every step of the way for a no shortcut top notch job.
I was an excellent student for two years in metal shop in high school. But we did not have carbide cutting tools. I went to college but I missed the metal work. I wish I could discuss your videos with my old shop teacher, Mr. Cullen. Cullen was a master machinist with GE for decades and when he retired he taught the next generation of machinists. Thanks Mr. Cullen.
What a superb job. That work you did with the silica bronze on the piston was not for a first timer!
amazing series, Kurtis! It always astounds me what a one-man business like you and yours accomplishes to such exacting standards. and Karen, you videography, editing, running commentary and sneezing on camera are Oscar worthy!
When machining becomes a routine in your life you pick up bird whispering as the next challenge. I like the bronze update. Cheers 🍻 and thanks for the video.
That gradient transition with the gray to orange paint... *chefs kiss* beautiful.
Thanks for the videos! They are so complete, soup to nuts. The work is fascinating, content is sterling, the filming is fresh and creative and videos would not be complete without the pup, the birds and the out takes. I give your channel 5 Stars, it’s very high quality.
👍🏻👍🏻👍🏻👍🏻👍🏻👍🏻👍🏻👍🏻👍🏻
Your attention to detail in each process is superb. I love the slo-mo clips of flying chips, it gives a better understanding of what is actually happening and video editing is spot-on. You two are an excellent example to other video creators of how to make good videos. I appreciate the explanation of what is happening and why and then showing the process. Adding Homeless being his awesome self and the rough-demeanor Kurtis feeding the cute little birds to the outtakes makes for an interesting video that I look forward to each week.
👍🏻👍🏻👍🏻👍🏻👍🏻👍🏻👍🏻😁
You have all the finesse of a surgeon and the experience to match
Men like you make the world go round. Thank you for sharing this!
As usual you both should be extremely proud of the work you do and the content you produce. Kurtis is a master at his trade and Karen your filming and editing is second to none!! I like seeing Homeless and now George and his buddy. It's all excellent!!
I was impressed by the application of the silicon bronze on to the piston, and the thinking behind it; a relatively cheap sacrificial wear point to prevent a much more expensive repair if proper maintenance isn't performed. Well done!
That reverse shot of the first boring at 5:42 was awesome.
That turned out very nice. It’s interesting to see how the process went from junk to new part.
I love how you turn those chunks of bare steel into beautiful machine parts. From Nagaland, India
Excellent series on this cylinder rebuild.
Another amazing job. Better than original OEM parts.
I subscribed to Matty’s channel after hearing you talk about him, his struggles, and the gofundme. It’s beautiful to see the love and care you showed to help that guy out. I could see from his last video how what you did, and him seeing how many people care, is setting him up for the best possibility of a successful battle with his cancer. You’re using this platform in a great way and you seem like good people. Love the videos.
I love to focus on the work Kirtis does, and I must say the shots and editing in this installment are 2nd to none; I loved the shots at the 5 minute mark. Thanks Karen (Edit: And Kirtis of course :)
Always look forward to your videos! Been watching for years now and I just cant get enough!!!
Love to watch what you six have been doing, always fantastic. I mean 6 because the family has grown hahaha.. Thank you so much for teaching us how well done things are done . My best part is when things don't go straight " get stuck " and the way you solve them, amazingly
I absolutely loved this episode. Curtis, you’re such a skilled craftsman and I really enjoy when you turn a rough chunk of steel into a precision part. Brilliant!
Cheers from Peter in Maine USA. I am a long time fan who enjoys you and you wife and your wonderful talent on videos. You folks do a fantastic job on everything, the dog and birds included. I really appreciate your content and commentary; very educational. I am an old fly fisherman and retired butcher but I love the stuff you do. Thank you.
Hey Peter thanks for sticking with us for the long haul!
Hey Peter thanks for sticking with us for the long haul!
I get up every day around 5:30 AM and on Friday, watching CEE clip before I even get to the shower and run out to work is like a religion. LOVE you guys! Cheers from Chicago :D
that's a nice touch with the silicon bronze. lots of other people wouldn't do something like that, which means better value for the customer. well done
Love seeing those blue/gold chips coming off the lathe! Puttin’ the heat in the chip where it belongs! Keep up the great work!
I enjoyed this series, K&K. I liked the weld buildup on the piston and the looping the o ring around the seal. Very crafty. All the best, Mart in England.
Hello from Boston Massachusetts USA 🇺🇸 you rock ❤❤
You are one of a kind! Congrats to the Camera lady, nice editing. Love the dog too.
It really is a pleasure to watch Kurtis take a solid block of metal and use his skills to make a well machined piece. I just go into an almost trance of relaxation watching him do the work !! Great work as always and Karen does an amazing job of filming, with Homeless bringing the good looks and fun.. What a team !! CEE for the win..
Thank you very much!
Homie is definitely good looking.
Exactly what I was thinking. His work brings me a calming mood and a fascination to watch. I like the sound of the metal getting worked and all of the different angles Karen catches of the process and of course there is Homeless,...... it just would not be a viable video w/o the "Safety Officer" to observe.
Excellent series! The bronze bands gave me man-tingles and the shot of the 90mm drill breaking through from inside the chuck would have made Ridley Scott stand and applaud. Are those crazy birds related to the extinct Kauai o-'o? Homeless was his usual legendary self, as well. Thoroughly enjoyable.
😁😁😁
The birds are Pied butcherbirds (Cracticus nigrogularis); they're related to the Australian magpie. The Kauaʻi ʻōʻō was, if Wikipedia is correct, a type of honeyeater - no relation to the butcherbirds or magpies though we do have honeyeaters of various kinds.
I think the birds are " keeping an eye " for a eagle or other predators from above :)... thanks for the video.
В этом видео шикарно всё и все.Крутой специалист. Блин мало того что всякие пластмассовые затычки есть, так еще и какой-то упаковочный материал. Чувствую себя дикарем из каменного века Птицы :)
Nice work guys, when birds tilting their heads, they’re normally a something they keep an eye on, either a plane or bird off prey. Keep up the wonderful channel.
The interesting thing about all birds is that they cannot move they eyes in the eyesockets. As a reason they have to twist and tilt their heads to change direction of their eyes. To look directly at ground or towards the sky, they have to tilt the head quite a lot.
@@MikkoRantalainen Correct. Most bird's eye globes are very much larger than the exposed part we see. This gives them exceptional visual accuity compared to humans but limits eye movement.
I can't explain myself why I've been watching nearly all of those episodes though, I love them all. Great work!!!
I never knew that watching a video about lathe & machining huge tools I'd be worried about the well-being of a bird. Hats off to both of you for doing an amazing job at great machining and making videos about it.
the shot of the bit breaking thru was Great!