Making a NEW Cylinder Rod for 90T Excavator | Manual Machining

Published 2022-11-04
This cylinder rod is damaged and has a very unique failure! This is the dipper cylinder rod off a 90 Ton Caterpillar 390 Excavator and part of the rod has shattered and cracked so we need to make a new one. This video shows the step by step process to make the new cylinder rod including machining, threading and welding. We start by machining the eye off the damaged rod in the lathe. We then use a new 150mm diameter piece of MnVS6 induction hardened chrome bar and turn it into the hydraulic cylinder rod before fitting and welding on the old eye. First we rough machine down one end of the rod before finish machining the end for the piston, cushion bearings and nuts. We then cut two external threads before flipping the rod to machine the other end. We machine a spigot to fit the rod eye and a taper for weld prep before fitting and tack welding the eye in position. We finish the job by welding the eye on and get it ready to be sent back to our customer

In this video we are using:
- Hafco TM-26120G Centre Lathe
- WIA 500i Weldmatic welder

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All Comments (21)
  • @N3xus_6
    Hi from Wellington NZ, I'm killing it at Polytech bc of this channel, everyone in class calls me Curtis. Whenever our tutor asks me how I knew, I quote a CEE episode. My whole class and tutor are subscribed. Thank you again team CEE
  • @artszabo1015
    I am a 71 year old retired machinist amongst many other trades. You have always impressed and educated me. Today you amazed and fascinated me. You actually re-engineered a very expensive and critical cylinder with great confidence. I am thoroughly impressed with the way you diagnosed the causes of the problems. Additionally you take your skills as a machinist and welder to an art form. As I have said before everything you do is industrial jewelry. Your over the top attention to detail and your concern for appearance is on a level that belongs to you exclusively, except for Abom 79 whose finished product is very comparable to yours. And then there is that lathe you used in this video. I have never seen a lathe as tight and solid as this jewel. Half of everything you do would cause violent chatter on any machine I ever used, yet that machine does it repeatedly with glorious finishes rivaling best the of the CNCs. You are truly an amazing individual, especially for being so young. I also find it hard to believe how much equipment you have accumulated at such a young age. Art from Ohio PS; I am an old prick that rarely ever gives compliments to anybody unless they really earned it.
  • @weevie833
    I am an Instructional Designer from the U.S.A. I have been reading the comments here about how your work on this channel has positively enhanced formal education in the machinist trade and I'd just like to say that you have influenced my concept of how people learn beyond traditional methods. Keep up the good work!
  • @JDnBeastlet
    Hey CEE Australia, I've been reading some of the comments about how you are educating and inspiring a new generation of machinists. This is truly incredible and you deserve all the credit that comes your way. Your videos are amazing and entertaining too.
  • @st3althyone
    This is one of the best ways to start the weekend. Having a cold beer while I watch Kurtis repair some big machinery. Thanks for always giving us your best. I hope your family is doing well and that you all stay safe. Take care, Kurtis, and we’ll see you on the next one.
  • @w.o.o.d.y
    Improving the design on a mass produced world wide machine part. Impressive stuff Kurtis, your know-how is limitless. You could have just replaced the part as standard and waited for it to break again, got more business in, but you have acted in the customers favour by doing the best job possible. Well done mate. Superb professional repair as always.
  • @johnson2207
    There are many things that make your channel great, but what I particularly like is that there is no music. The sound of the machines adds so much to the quality of the experience, and the quiet moments in between are very relaxing in contrast. Your videos are very well done. Thanks for making them.
  • @jonp5760
    I like that you added a clock in the background for the time lapse welding. It really helps us see just how much time you put in to welding all that up.
  • This guy is a one man army for such beautiful and robust repairs 🙂
  • @gav2759
    This is what we have come to expect on your channel. The laser like focus, the assuredness, the proficiency that says "no one can do this like me". That's why they call him "one take Hommie"...Oh and the other guy can turn a bit too.
  • @numazuchi
    That gong when you lifted the rod was just beautiful.
  • I’m a millwright (aka industrial mechanic in some areas) and to see this kind of stuff is so cool and I love how Kurtis explains things without seeming above anyone and to actually take the time to modify it to help the customer is amazing. Love the work and videos
  • @markfiges999
    Great vid Curtis, ....those cracks and fractures were something brutal - not seen it that bad before, thanks to Karen for the filming, a pat for Homey and hello to George, you all take care and stay safe.
  • The explanation in the beginning was great! Superb work as always.
  • @Dmenbiker
    Karen and Kurtis... It's hard to believe but you two are getting better than before... I watch in awe as the new piece comes to life... It makes perfect sense why you are a one-man-shop... Where could you ever find someone that could be left alone in your shop that could be trusted to follow you in quality workmanship...
  • @hendriklubbe
    Loved the sound of the rod ringing like a church bel when you lifted it from the pallet! DUDE, what you do with metal is witchgraft! RESPECT Curtis!
  • @DPeanut
    No better way to kick off a Friday than with a fresh video of machining bliss!
  • I really liked the "hyperlapse" of the lathe work with the button insert. It really serves to convey how the operation is performed that would be difficult to see at regular speed.
  • @QuantumTeapot
    Hey guys, awesome video. I'm a mechanical engineer working for a company that designs/constructs mines. We're based in Yatala and sometimes need shafts made or other various machining work done. Nice to know you exist - will keep this in the back pocket for sure. Cheers