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Old 04-22-2012, 02:28 AM
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clive clive is offline
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Default Shaft repair welding machine

Not sure if this is the right section but here goes. Has anyone built a machine to rebuild shafts with wire fed welder? I have found a spit motor that is pretty slow to start with and with a couple of sprockets could slow it down a lot more. I am looking to drive a shaft and have the handpiece fixed to follow a threaded rod as the shaft turns and build up the shaft that way. I seem to recall someone did make one some time back but can't remember the details.

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Old 04-22-2012, 04:04 AM
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Maybe you can rig up two variable speed cordless drills, one for the shaft and the other for the screw.
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Old 04-22-2012, 06:07 AM
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Yes, I thought about that but decided I could run it all off the one motor using a reducing sprocket drive for the shaft and a same speed sprocket drive for the lead screw. But I'm certain there has to be a better less complicated way than that. When I machined a lot of reclaimed shafts the weld was like a thread in itself, really neat and a pitch of say 8 - 10 threads to the inch.
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Old 04-22-2012, 07:52 AM
Jake98 Jake98 is offline
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Maybe start with one of these..
they have cheaper and more expensive versions. I've been saving an old industrial sewing machine table with the drive system for some kind of future project. Originally was going to use it to wind coils for antennas, but never got that far..
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Old 04-22-2012, 08:11 AM
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Find and older lathe with gear box. Then use a rotable ground clamp since the bearings in the head would take a beating.

Rotoground work clamp would work. I'll post up pic's later.

I bought the clamp on ebay then I ended up getting the rotory part on ebay to.

total cost was 240.00, new they are big dollarts... I have heard that you can make up your own with carbon arc torches using the carbons to run against the shaft but figured for ease of use I'd just put one together from ebay parts.

The lathe would allow for you to fine tune your bead spacing and the multispeed head should be slow enough.

Auto feeding the head would give the best results.

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Old 04-24-2012, 09:12 AM
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Crankshaft grind shop re-weld with a similar machine (except the tail
and head stock's offset)

I had a cleveland shop re-weld a crank for me, ran .030 er70-s6
standard MIG wire, but used sub arc flux, and ran it as a sub-arc machine.
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Old 04-24-2012, 12:23 PM
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monckywrench monckywrench is offline
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Some folks run a flexible strap-style woven copper automotive ground strap around their shafts. I think the thread might even have been on this site. Easy enough to gently spring load to maintain contact.
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Old 04-24-2012, 08:22 PM
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LW Hiway LW Hiway is offline
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Clive, thought you might like to see something like this done more or less on a large scale.
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Old 04-24-2012, 08:59 PM
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Here's my take. I am building another project, but would probably work for what you want to do. I have a 90VDC 1HP motor and a 60:1 gear box. They are bolted to a section of 2x6x3/16" tubing. Just put a lovejoy on the output and attach your all thread or acme screw. Put some pillow blocks at each end I would think that would do you for drive. Also the motor has a speed controller. Got mine off of a treadmill.
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Old 04-26-2012, 09:28 AM
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For auto weld you need infinite control for the speed of the shaft you are building up. Remember the circumference of a shaft grows at over three times the diameter. So to accommodate a wide range of sizes it may be best to drive the shaft with a couple of rollers like the pic. I have once seen a setup to build up track rollers and idlers for earth moving equipment. Don't remember much but it was wire fed and could handle up to 48" diameters, I'm not sure how small of a diameter it could do but most rollers are under 6". I should stop by some day and see if its still where I last saw it 18 years ago.
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