Making the NEW Cylinder Barrel! | Hitachi ZX470 Cylinder Rebuild | Part 2
We've got the damaged hydraulic cylinder disassembled now it's time to make the new barrel! This video is Part 2 of rebuilding a stick (dipper arm) cylinder off a Hitachi ZX470 excavator. In this video we show the complete process of making a new cylinder barrel including machining apart the old barrel before machining and welding together the new barrel. We also show fitting on the head flange using an interference fit, pressing out the old bushings with our 150T hydraulic press and honing out the heat affected zone in the new barrel! Stay tuned for the next video of this cylinder rebuild where we make the new piston and reassemble the cylinder!
MISSED PART 1?! Watch it here: kzhead.info/sun/f76Ggrhlhnira4U/bejne.html
In this video we are using:
- Hafco TM-26120G Centre Lathe
- MetalMaster HPM-150T Hydraulic press
- WIA 500i Weldmatic welder
Join our channel:
We upload new videos every Friday at 5pm AEST! If you want to see more of our videos click LIKE & SUBSCRIBE! You can subscribe to our channel here: bit.ly/ceesubscribe
Want Early Access & Ad Free videos?? Join our Patreon Community: www.patreon.com/cuttingedgeengineering
Official CEE Merch shop: www.ceeshop.com.au
Check out our AMAZON store and explore our favourite finds that we use in the workshop:
www.amazon.com/shop/cuttingedgeengineeringaustralia
To see more follow us on online here:
TikTok: vt.tiktok.com/ZSdHhtN4h/
Instagram instagram.com/cutting_edge_engineering
Facebook facebook.com/cuttingedgeengineeringaustralia/
About Us:
Our channel is all about showing you real life machining work from our workshop on the Gold Coast Australia. We specialize in manual machining, hydraulic repairs and heavy fabrication for the earth moving, mining and civil construction industries. So if you're a machinist that wants to see some big gear in action be sure to subscribe to our channel right now. We upload new videos every week that show lathe machining, milling, welding and all the good stuff that comes from a machining workshop. If that sounds like something that you would enjoy seeing, then make sure to join us by subscribing!
#australianmachinist #machineshop #machinist
MISSED PART 1? Watch it here: kzhead.info/sun/f76Ggrhlhnira4U/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
Hello Queensland........thanks for another great video, cheers from the Other 'Sunshine State' Paul
787
You spun the barrel in the lathe, you didn't flip it.
Have an awesome weekend guys, cheers for the great content.
Anyone else unable to LEAVE a comment other than a reply????
As long as I got here so early tonight, I'll say this. As an engineer, I can't begin to tell you how much I respect Curtis' knowledge and capabilities. I don't give that out lightly. It's a rarity, and you're quite the rare breed. These videos are the highlight of my week. Thanks.
hey mate thanks very much I appreciate that 👍
@@CuttingEdgeEngineering I got up in the middle of the night to watch this. LOL Cheers.
*Kurtis
@@teeanahera8949 *Karl
Agreed, as someone who has an engineering background I've got a lot of respect for Kurtis. He is rare breed indeed.
This is the best machining channel on KZhead, no contest. Thank you Curtis and Karen!!!
Wow, thanks mate we appreciate it!
@@CuttingEdgeEngineeringI really look forward to your videos every week, and enjoy every minute. I really like how you speed up sections of video so we get to see all the steps but it doesn't take so long. Thank you!
I agree strongly! More importantly, it's the only channel with Homie! ❤
Totally agree. Great stuff, great information and excellent video work. They are a super pair. So many channels where people love their own voice and just blab away. And no 'hidden' product placements either. Just strait up factual information. Love them both
Agreed 👍
Thank you for not putting in any corny music as filler in your videos. Great editing
Go cart with a fan and plastic bag.😂 Enjoying again these vids, suberb work from both of you. Homeless is still the real star. 😎🇫🇮
Are you a snooty helicopter guy too?
Karen is filming and giggling, Curtis is working with a straight cap, Homeless is ripping apart packages and George is screaming, singing or whatever these sounds are called. I suppose it's a normal Friday at the Gold Coast and i love it 🙂
Karen is filming which is also working, otherwise no KZhead film. So, thanks Karen👍👍👍👍
@@erikbarsingerhorn4485 which, not witch!
@@rjung_ch Corrected👀😅
Witch wurd wuz speled rong,eye dead ant notis!
@@petersmart1999 🤣🤣🤣
My dad was a carpenter for 45 years before he retired and his shop had sparrows that would roost there in spring. They built nest and along a wall in the back of the shop and every year they would raise a new clutch of young. My dad cut a hole on the door for them to fly in and in and out of, and they would zip in and out all day bringing in food for their babies. I only remembered that when I saw him feeding those birds. Good childhood memory, thanks buddy.
Sparrows are great birds
Watching you tap the bearing off the cylinder after machining away the PERFECT amount of metal has convinced me that you are actually a wizard. Your secret is out and your clever rouse has been foiled.
Like the homemade lifting bracket for the tailstock chuck. Simple and effective.
Kurtis properly loading an old cannon is the epitome of this episode!!! 😁
that was my initial thought, too.
@@raudi42same.
same over here
He should check into the laws down under and make a small gauge cannon doesn't need to fire shot just straight black powder do it for the GIGGLES
@@michaelnieman6218A big old George scarer?
The butcher bird song was beautiful. I'm so glad you captured that for overseas viewers. Considered one of the best bird calls in the world.
Karen possibly moved from NZ to Australia because she got tired of the Kiwi mating call...
And ALL THAT for a fraction price of a new one... Sincerely impressive.
Hi Curtis, Karen. Have you ever imagined that your videos will be watched all over the world? Stunning work as always, and I love your little bird ZOO, lol :)
hey mate, we honestly never expected our channel to grow as big as it has and to have so many supporters around the world!
You two a wonderful job making videos. I enjoy them and I’m a woodcarver thanks
Love the addition of the clock, shows how long in real time things take to do, great addition idea.
You all have created quite a monster with all the Georges flying around these days. Take care and have a great weekend!
Worse yet... They don't even TASTE that good, and they're bloody finicky to pluck too!
@@trevorvanbremen4718 Clay wrap and bake whole (well, maybe gut it first). All the feathers will come off, hopefully, with the clay. (Do not do this with the Georges. Eating birds, yes. Georges, no).
Soon the magpies will take over and it will just be a magpie channel with humans in the background at most
Homeless is such a happy dog! Makes me smile every time I see him 😊
I'm the same ,every time I see him running towards the camera I have the soppiest grin. I've tried not smiling and it's impossible😂
I definitely like the way you work Curtis. I'm sure you're plenty strong enough to lift a lot of those parts but you're smart enough to use the crane and the forklift. I was a mason for 20+ years. I've done more than my share of heavy lifting over the years. Now that I'm older my back is paying a heavy price for all the hard work. Trust me my friend your back will thank you when you're older. You young guys can learn a lot from Curtis so pay attention.👍🏻
As a heavy vehicle mechanic myself, i totally agree, back when i was doing my apprenticeship little was said about OH&S, steel cap boots and overalls was about it. Curtis is a smart lad he will do well.
@@fredzephire4071 Exactly. I agree. We didn't even wear hard hats unless the general contractor required them. A lot of things have changed since my days as a mason.
Brilliant advice for young people in school. That kind of advice is something that definitely needs to be made each morning like the pledge of allegigance
For every Kurtis, who happily tells us how he goes his job there are 100 others who say nothing, “so you won’t know as much as they do”.
I remember picking up a “normal” hammer for a job while the experienced guy had what looked like a toffee hammer. Within minutes, I was struggling with a too heavy tool. I learned a valuable lesson - use the right tool for the job. When heavy stuff has to be lifted, your own back is never the best tool for the job.
Maybe you get tired hearing the same old stuff, but the quality of engineering and video recording/editing is superb. Real professional stuff which, even as a layman with no actual need to know this stuff, is a real pleasure to watch. Great job, both.
I work a late/swing shift so it’s always nice to watch someone else work when I get home, LOL. I don’t know why I think that’s relaxing but it is and there is no comparison to all the other content on KZhead, your unique content is in my wheel house as to what I work on all day and I enjoy expanding my knowledge. Hard to find people these days that put workmanship, craftsmanship and pride in their work and I appreciate the effort you all make and share with others. Big thumbs up from the STATES 🇺🇸
Ive been working a dupont swing shift 12hrs for just over 20 years and I tell the new guys youll never get used to it only build a tolerance for it. whew!
Love the Butcher Birds. I get woken by their calls every morning. Mine sound the same but they play their own unique tune. Love the machining as well. 🤠 Cool two handed turning. Most people don’t appreciate how difficult that is.
Cutting edge engineering. Home to a superb Engineer, a brilliant film producer, a multi-talented four wheeled drive parcel examiner, birds, helicopters and a plethora of tools and equipment. Excellent combination, not to be found anywhere else in the world and addictingly entertaining too. Cheers guys.
Birdies! I didn't know George sings for his food 😊 Geez you both have skills most of us could never dream of having. The details in the filmed content all the way through to the knowledge and honesty shared by Kurtis.. Keep up the good work...
The fact that Curtis is a machinist, mechanic, engineer, and Disney princess is just awesome.
I love the circling white dots ... Too funny ... Sorry Curtis ... Thanks for sharing ... Stay safe and well ...
After a week of bs in the office, I so happy to see real work done right, a seldom thing to see these days
Gday Kurtis and Karen, sounds like hitachi have put thought into there cylinders with the simple things like a centre, absolutely awesome to see the hone doing it’s job again and it certainly wouldn’t be hard to over cut each side of the effected area, George and his mate put on a good song this week to, great job mate and thank you, have a great weekend, cheers
👍
Your experience shows in little things like machining the steady bands down to the same diameter so you don't need to reset the steady when flipping the cylinder. A random guy like me might just machine them until clean and then lose time re-centering for a different diameter.
Special bird whisperers in this one, so nice. The song was special as well.
I turned off TV and got hooked watching this craftsman at work.
Hi, from Sacramento, CA USA, love all the vids, incredible videography and incredible attention to detail. Keep it coming and more puppy shots please . 😊
I'm west of you in Sonoma County
Hey mate thanks so much for watching & commenting!
I’m in Woodland
Should I put on "It's a Small World" for us? 😀
Kurtis, I always give you praise because your workmanship and craftsmanship are second to none. But Karen, your editing and camerawork are getting amazing!! Your switches between not only shots but themes as well is flawless! Let’s be honest also, you make Kurtis sound like a Nobel laureate and we all know words are not his forte. I’ve never had any problems or issues watching your videos but they’re now so seamless it’s like watching a high dollar production! You mam, may have missed your calling.
Drinking whisky, listening to the rain lashing on the windows, watching someone on the other side of the planet machine metal. Am I living my best life of what!
How goods that 👌
Cheers Curtis and Karen for my Friday night fix.From a very happy Scotsman living in the south o France who found you guys on youtube .
I love your work! Your wife does great camera and editing! I think homie was wondering where his package was and went to search it out 😂 love the birds !
Kurt, I am very impressed with the variation in thickness of the barrels walls. When you make the cut on the lathe, we can see that the eccentricity is absurd. I notice how your welding (done manually) is much superior to original welds of these barrels, which are done through automated processes. Your welding is very well distributed, with constant thickness. Congratulations on your skill. Greetings from Brazil.
Brazil is well represented as intelligent people such as your self enlighten the entire world 🌎
It makes me angry. He says that 30 minutes of welding was needed at 20:00, but he only weld for a few seconds in the video! Nobody can weld that fast
And there is NO FOOTAGE of the welding at 30:08 …. How do we know if he even did the welding???
I love the sound of the Australian magpie, it brings back memories of my trips to Australia. I stayed at Undarra Lave Tubes Resort, I slept in a tent and lying in bed listening to the birds was so serene and therapeutic.
Curtis stepping away from the largest sand blast cabinet I've ever seen... "This is too small and more of a home hobbyist cabinet"
thankyou Karen and Curtis for our weekly lesson in barrel making and also having a nature element, feeding the wild birds and learning about their different calls and eating habits. you guys are a great channel to watch. awesome job as usual Curtis your the best machinist i know by far. there is no limit to what you can do. take care guys.
He sounded like a gate that needed lubricating at one point!
Having a crane that would reach the welding and honing areas might be a good investment 😮😅
This guy really knows his trade! The fact he's so young is even more impressive. Love the channel.
YOU ARE A PROFESSIONAL,I'M 80 AND HAVE HAD A LARGE TOWING BUSINESS AND LAST A SEMI TRUCK SHOP, YOUR WORKMANSHIP GIVES ME HOPE FOR THE FUTURE GENERATIONS AND I CAN SEE YOUR ARE HONEST IN YOUR WORK,MAY GOD BLESS YOU IN YOUR LIFE
Glad to see that compound at 30°. I enjoy watching you do steady rest work. When i was working at my last job i did all the steady rest work. I've made custom cylinders from scrach with honed tube. Made many a rod and piston. 30 years machining and 20 of it programing large lathes. So its very enjoyable and satisfying to watch you work. With your precision and attention to detail. Thanks for you time and Karen's time and effort too. I know she has a tough job making you look good. Lol...your faithful watcher, the disabled machinist.
These barrel rebuilds are just captivating to me. No matter how many you do, I will still watch every one of them. They are similar but each has a bit of a difference. Such as this one having a cast flange. Great to watch!
So enlightening to ger such comment from all over earth 🌍
I love when you put the shots of the yard birds in there. My cats went nuts when they hear their calls!
Watching Curtis work is one of the most relaxing things to watch on KZhead. 🎉
Top notch once again Kurtis and Karen. Even the Magpies have got into the act of singing Curtis praises, he is now an honorary Australian Princess. Thank you guys you make the start of the weekend a joy.
Butcher Bird...
Pied butcherbirds (Cracticus nigrogularis) actually. They are related to magpies, probably the easiest visual difference is that magpies have black undersides and walk rather than hop.
@@gazzafloss I've given them a butchers and they are Magpies. :)
@@Horus9339 nah!
@@ithecastic *Kurtis
Those button inserts are beasts. I love this content but i don't know why, I don't have any experience or dealing with engineering for work or hobby yet every week Im glued to the videos. Thanks for the time and effort you take to make this content its really interesting and you guys have great chemistry and of course homeless is awesome. All the best from the UK
Quality .... Thank You Kurtis and Karen! Quality Knowledge, Workmanship ... And Stunning Editing And Style of Vid ... No BS NO Montage BS with Crappy music .... just straight as a die. peace
Not a wasted motion Kurtis, a pleasure to watch. I get a kick out of Kurtis and the birds, cursing them one minute for being noisy and the next feeding them. Obviously a true animal lover he is :-).
Nice job, as always Curtis is an expert and Karen is the best cameraman
unreal workmanship and the wife filming never miss a show so good to watch keep it up cheers.
Reminded me of once upon a time. I took the gloves loose in the bead blaster at work and turned them around backwards. So funny when the next guy “tried” to use it. He had Supervisor order a new set of gloves, but in the mean time I reversed them back to normal and was using it. Super came by and told me to stop as the gloves were messed up. Really? They seem fine to me? He stuck his hands in and then called the other guy and asked him what was wrong with the gloves? We had a spare set for years before using them.
Kurtis "Button Insert" Allen is back in action! I love it when the button comes out cuz we are about to get some meaty freehand turning. That and some amazing welding. Watching you run the lathe is just too much fun.
Yeah, those buttons seem to cut really well, depth & speed & finish, so still surprised that it isn't used more, much more, for all facing & turning, even boring and not just hogging out those welds! An to top it off, it ain't got just 3 tips, not a infinite number all the way around but way more then 3!
Good one Karen - great editing created an interesting video, good job picking up the center height issue and, "mint" that came out of nowhere!
Buenos días, ¿cómo están? Siempre espero los viernes para ver su excelente trabajo, y también el excelente trabajo de la Señorita de la cámara. Saludos desde México.
I noticed Curtis always welds counter-clockwise (pushing weld in, NOT dragging weld around OD). A real pro.
Thank you CEE for another fantastic machining video enhanced by the beautiful song of the Pied Butcher Bird. Kurtis the "bird and machining whisperer".
I suggest some time in a future video you might mention your big lathe's leadscrew/feed shaft support. My nephew who's been in industry for 30 years had never noticed one before posed a question (I could at last answer) and I thought others might be curious too.
J'attendais avec impatience la deuxième vidéo, regardé avec un immense plaisir, toutes mes félicitations, car en France il n'y a pas beaucoup d'artisan de cette qualité !!
Cutting edge engineering you are getting replies from all over earth 🌍
You guys have the most interesting (and expensive) way of making steel wool i’ve ever seen. 😂😂 Keep it going and thanks for sharing
Love the birds calls.
Your attention to detail is beyond reproach. Always a blast to watch.
its interesting seeing how another shop does this
The modem sounds in the outtakes got a real laugh out of me! Cheers from New Hampshire, USA!
I don’t know for how long I will be able to watch you do the same things over and over. My guess is 15 to 20 years.
Thank you Mr. Curtis for this useful lesson And thanks to Ms. Karen for making the activity enjoyable when she excelled in photography and directing I look forward to seeing you every week in Kingdom of Saudi Arabia
Good job, glad to see the birds still around, my wife and I live on the side of a mountain in a forest. We have so many birds around which we feed even got birds which sing through the night too. The honing machine is awesome and must be very handy not having to send work out. Sometimes the weld prep took longer than the welding, but we always made sure it was done right. Great post. Thanks Kurtis, Karen and of course Homey 👍
Clever tool you have for carrying/installing the rotating tail chuck!
que perfección 👌👌muy buen trabajo 👏👏
its getting there. soon you will be able to re assemble the parts. You make it look easy. Good video Kurtis. Its good when you have the tools to complete this kind of work. Hope to see the next part next week. Look forward to that video.
I'm glad you captured the butcher birds singing. They can actually produce a number of different songs. Great birds.
Its good to see how clean, tidy, and well lighted you keep your shop. I've seen other machine shops that are dark, dirty, and disorganized. Even your bird friends sing their approval from the rafters, ignoring the occasional cuss words they hear. Good on yer, mates.
That was another great video. I love seeing that big hone in action and Karin was quite enamoured with George and his cohorts. We're really looking forward to seeing the creation of the piston and final assembly. Best wishes to you three from Bruce, Karin, Halgrim and Bella. We wish you a pleasant and joyful weekend.
Great video and words to live by… Always keep an eye on your stones.
The alignment of that head has to be spot on, no room for error there...
Most satisfying watching you tap the ends off after machining till it just brakes into the barrel
Kurtis, you make everything appear really easy - a true Craftsman indeed - and a great pleasure to watch!
24:15 - 26:05 was some great capture and editing. I guess Kurtis did something too. 😅 Amazing stuff. You both always start my Fridays with a smile, thanks. An example of professionalism every week. PS: My goof's get excited hearing Homeless open packages. It makes their Friday morning a treat as well!
So appreciate the engineer, such a therapeutic and admirable video
If it was easy everyone would be doing it. Great job Kurtis,
1:49 Hilarious! Your CEE notepad says "F*CKING MUNTED" on it! HAHA!
Haha good spotting!
Yay! We got to the honing machine 😉 Thanks guys. Top notch 👌
Great work both. Could i ask curtis to explain on a video how the honing gauge works and why he lifts it up and down when measuring the ID. Have a good weekend guys and Homie. Love from my blue staff Rita ❤
Retired Boilermaker, U.K. When I finished my time, I was told by my brothers that I'd never be rich, but I'd always be able to keep a roof over my head, & put food on the table. Turns out, they were right. I've had some shitty jobs, but most were O.K. Always working for someone else. I was never in the position to work for myself. I'm an admirer of yours, some of your jobs are really interesting! I've done some awesome ones, too, but never had as much fun as you're having. Long time subbed, it's brilliant watching others getting their hands dirty! 🤣 Keep well, Kurt. 🤠👍
O sorriso da Karen, o canto do passaro e o profissionalsmo do torneiro tudo é lindo neste video
Yaaaaaaaaa….it’s Friday, time for my CEE fix! 😊 makes my day every time! Thanks K, K, & H.
Man, that's a nice machine. I forgot if he got a demonstrator deal or something special. Here in the U.S. those things sell for over $50k USD more than 10 years old without extensions. Can't imagine on the other side of the world, much less new. To my knowledge for at least 50 years there is one name in hones in the United States that every young future car enthusiast knows before ever rebuilding an engine. Sunnen, specifically the CK-10. Well, that and AMC, Berco, Kwik Way, Peterson, Rottler, Van Norman.... Makes me smile seeing Sunnen, CAT, John Deere etc in AUS videos.
Great work sir you are awesome 😊❤
I just love the swarf from the button inserts, it's kinda pretty. But I also like the long pig-tails from the parting tool as well. How long to clean up after a job like this? And another great video is done, well done to both of you! Excellent editing as always Karen.
Love watching you guys 🔥🔥
Utterly amazing. surprising that it is cost effective to rebuild vs. always buying a new replacement. never realized how much engineering goes into something as "simple" as a cylinder.
Always blows my mind that good quality welds are so strong
Another brilliant video from CEE waited a week for part two,but well worth it.
*Cutting Edge Engineering Australia* Bravo well done, always a pleasure to watch, thanks for taking the time to bring us along. GOD Bless.
Your business model is very rare these days. When something leaves your shop, your name is on it. It has to be perfect. Wish I could trust the trades here like that.
Heating the outside and cooling the inner liner was how they would construct the gun barrels for battleships. The drag on the inner liner from the projectile traveling down the barrel was so great that it would stretch the inner liner. The crew would have to periodically cut off the piece of the inner liner sticking out of the thick outer part of the barrel. In WW II, the 16 inch guns were only good for about 300 rounds before the rifled inner liner had to be changed. Firing a 5 foot long, one ton shell, using 660 pounds of propellant would do that.
I gotta say, I do love when a vid hits, because that's my cue to get the weekend started! it's 5pm, baby! Is it getting a bit warmer for you guys up there? Pretty sure we're already in summer in Melbourne 😂🤣 On ya mate
Hey mate! We're getting pretty warm sunny days now, nights are still a bit fresh but summer is definitely on the way 👍
@@CuttingEdgeEngineering I swear Bunning's already has Christmas sales up, and that's better than any calendar to know summer is coming 😂
@@caffienatedchaos If you want to know when spring is about to arrive, just look for the fruit mince pies in the supermarkets.
Really strange. I was going ask if Karen ever catches "mistakes" or "something's just not right", and there she goes and does it! 🙂
Thank you Curtis and Karen!!! The Kookaburra's are very loud for a small bird. LOL Hello from the U.S.A., Pacific Northwest, 50 miles North of Seattle, 100 miles from the Canadian Border. Thanks for sharing.. Sometimes I think the out-takes are the best part of the video's. The best is when Curtis catches a bad case of Hoof & Mouth. That's when it seems Curtis can't take his foot out of his mouth. You guy's are such great sport's to share the GOOD and the BAD and the UGLY. Ugly = Curtis take 57, wait what was I saying, okay Take 58, etc., LOL!!!
I just had the epiphany that both cuts for the steady rest are the dame diameter. I am sure others knew this already, but when you flipped the cylinder to cut the other end off, the lightbulb went on. Again, superb content.