Challenging CRACKED Cast Iron Housing Repair! | Flame Spray Welding

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Can we fix this cracked cast iron transfer case housing!? This housing is off a Caterpillar 966K Wheel Loader, there are multiple cracks through the bolt holes into the housing so we’re going to have a go at repairing it! Repairing cast iron is always a challenge because of how ‘dirty’ and brittle the cast iron material is, and repairing a large and thin housing is one of the most challenging parts to try and repair. For the repair we will be using our preferred method of metal powder and jet flame spray gun with oxy acetylene. We also show the process of dye penetrant testing to show the cracks and grinding them out before using flame spray welding. Will this repair work or fail?!
In this video we are using:
- Dy-mark Flawchek dye penetrant system
- UTP Variobond flame spray gun
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18 май 2024

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Комментарии : 3,4 тыс.

@CuttingEdgeEngineering 8 месяцев назад

Hey everyone 👋 We've unfortunately had delays getting seals to finish our Hitachi cylinder rebuild this week so we've got this cast iron job videoed instead! Hope you enjoy it 😄👍 *HELP SUPPORT MATTY's WORKSHOP CANCER BATTLE* Donate here: gofund.me/6ad05239 RU-vid Channel: youtube.com/@MattysWorkshop 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

@fisheatinweasel 8 месяцев назад

It is too a zoo!

@64Pete 8 месяцев назад

Have a crackin' weekend guys. I'll see myself out.

@user-oe9xe8mv6t 8 месяцев назад

Homie gave me a decent laugh with his box attack. It didn't stand a chance.

@stuart4858 8 месяцев назад

With cast iron that noise, once heard can never be forgotten. Bloody good effort though. Stuart from Sydenham Vic

@MajesticDemonLord 8 месяцев назад

@@isthatbikedieselmate That Crack was mad! I jumped in my chair when I heard it.

@paulhannoever7680 8 месяцев назад

The fact that Kurtis is willing to have a failed project published just shows how professional and confident in his skills he is. Accepting ones own limits and not being afraid to state them really shows character. Also not charging the customer! No wonder kurtis has so much to do, good on you!

@islandofice902 8 месяцев назад

This^^^ I've worked with cast a few times and my record isn't great. A big part like this? Doomed to fail, but a great learning experience. Hopefully the customer offered to at least cover the materials cost but I'm sure the honesty and attempt will pay dividends later

@josephkisner5997 8 месяцев назад

Dude...not too long ago I had a case from a pneumatic jack hammer...NO MATTER WHAT I DID... as per recommendation...DID NOT MATTER!!!! Cracks persisted and though it was considered a loss anyways it was surely lost after. Huge bummer, I didn't learn much because my boss knew less than me. Huge bummer, I really wanted to get it done. Either I missed something or did something wrong consistently 😂. Though watching all the nickel ball up during gouge was interesting. I feel like that was indicative of something crucial. Oh well...I'm a librarian now😂😂😂😂

@jmaxim80 8 месяцев назад

Exactly 💯

@y_a_r8080 8 месяцев назад

Dude. Spoilers(

@minter1013 8 месяцев назад

yeeep just shows you how good he is, what a legend !!!

@dystopianlucidity4448 7 месяцев назад

The slow character development of Kurtis turning into a Disney princess with the birds is priceless. Homeless getting better and better wrecking packages is hilarious. I commend you for posting a failed repair, but often times our failures teach us more than our successes, Cheers to all three of you. Much love.

@frankblack1481 7 месяцев назад

He’ll be singing next

@dystopianlucidity4448 7 месяцев назад

@@frankblack1481 lol! I’m waiting for the birds to match his whistle. But you gotta admit, he is magical.

@brentmitchell6411 7 месяцев назад

I'd pay good money to watch Kurtis the Musical@@frankblack1481

@verteup 7 месяцев назад

the dog opening he packages is hilarious. he opens cardboard better than i do with a knife.

@benlund3905 7 месяцев назад

Homie will save the failed cast iron. I have full confidence.

@davinanderson9832 7 месяцев назад

As a foundry engineer who works with ductile iron all the time, CAT is notorious for isolated thick sections in the middle of thin sections geometries… this creates a lot of residual stresses in the solidification and cooling process. Drill holes to add stress concentrations and now you have a casting destined for failure! As always, the CEE content is great!

@infoscav 7 месяцев назад

great to see this insight, the large final crack was exactly like you said, he colder casting could not handle the expansion of the thick heated section with the ring

@teamidris 7 месяцев назад

And maybe too much bearing load? The crack is on the outside, so the force was pushing outward. And the bolt hole cracks feel more like fatigue than impact

@David-xl8zf 7 месяцев назад

You´d need to engineer some casting forms that can be heated in respective areas then. 🤷‍♂ I suspect tho that either those impurities or inclusions were on the upper end of the "go" spectrum in roentgen or it has been run with almost no oil and been hot.

@willybones3890 7 месяцев назад

QUESTION: If that housing was brought up to nearly cherry red and THEN welded or spraywelded and then put back into an oven and slowly brought down over time and then held at like 400° for a time and then just allowed to slowly cool or buried in sand and allowed to cool...would it crack?

@teamidris 7 месяцев назад

@@willybones3890 it wouldn’t crack, but it would anneal and settle. And the holes would all settle into happy positions. It would need to be fully machines again :o(

@clintwoodworth8695 7 месяцев назад

I am a one man auto repair shop in Indiana. I've had your videos playing the shop last few days. While your workmanship is top tier and integrity is first class, I'm most impressed by your time management! You're never rushed, never stressed, and I have no idea how that's possible!! Please tell me your secret! Also, I think an "unboxing" series from homeless would take over the internet.

@meinereiner5832 Месяц назад

Er ist selbstständig und hat keinen Chef der ihm auf die Nerfen geht.Er ist sein eigener Chef.

@tda2806 8 месяцев назад

A large, complex casting like this, which has had multiple machining operations, been stressed through use and developed cracks without any obvious reason was always likely to be a lost cause. I hope your customer watches this and realises the skill and effort you put in to try and achieve a good outcome.

@GeorgeLittle-ft2yx 8 месяцев назад

Couldn’t have said it any better myself 👍🏼👍🏼👍🏼👍🏼

@mrb.5610 8 месяцев назад

Wonder if it was a flawed casting in the first place if there were jo obvious signs of what caused the initial cracks ?

@helplmchoking 8 месяцев назад

@@mrb.5610 there's always a chance, though Cat typically have good quality castings from what I've seen, you almost never get this kind of thing without any other damage or obvious issues. Not a job I'd want to take on regardless, cast iron repairs are a bloody tough thing to get right, especially something as big and complex as this

@GeorgeLittle-ft2yx 8 месяцев назад

@@mrb.5610 I was wondering that also. It just seems strange no visual damage yet cracking occurring? And then all the cracking happening when trying to repair, something fishy going on there…

@SeanBZA 8 месяцев назад

@@GeorgeLittle-ft2yx Residual stress from whatever impact cause those initial cracks. Either the shaft got clobbered, or the one wheel was suddenly bound up with a large rock or ditch, and the shock through the transmission caused the initial cracks, but also left a lot of strain bound up in the bulk of the thin side. Just needed enough heat to stress past the yield point, causing the crack, or one of them spread from the heat input to the point it hit the stressed material, which could have been there from when originally cast. About the only way to have prevented it would have been to put the entire casting into an oven, and taken it up to 800C for 24 hours, then let it cool at a controlled rate of around 20C per hour to room temperature, which would have released most of the stress, and likely shown the casting was badly distorted as well. Big oven, and also inert argon atmosphere as well. Would suggest as well the new casting is bought along with a new output shaft, as that likely also has some buried cracks in it, which probably will show up, with eddy current testing or gamma inspection. Might be cheaper to buy the entire unit ready built, as that gives a warranty on the part.

@assassinlexx1993 8 месяцев назад

In the shipyard they had large cast part on a large bed of coal with fireproof blankets on top. They repair it right in the burning coal. After that still under the blankets. They slowly let the coal to burn all up and let it start to cool. This was not a one day job. Full marks on trying to fix a massive cast iron part.

@danielrauer5864 8 месяцев назад

Or they fully cover the pieces in sand. But in any case these shops still cannot save every piece.

@assassinlexx1993 8 месяцев назад

@@danielrauer5864 So true. Some cast have so much crap it the steel. It make you wonder if they ever use flux to remove the trash

@gavinferguson 8 месяцев назад

good try dont thin you had much chance very poor metal to even crack like that.

@echollis123 8 месяцев назад

I guess that's the way the other guy who is so busy does it, by heating and cooling the entire piece over time. Using an oven that holds the entire piece and reheating as necessary. Kurtis isn't setup for it and the result shows. A most interesting video.

@gacherumburu9958 8 месяцев назад

My thoughts too!

@daves8407 7 месяцев назад

As always, solid work. You can't save everything, but we sure do like to try. I worked on the railroad here in the U.S. as a Carman (train car repair). All the couplers are cast and part of our job was to look for cracks in these components. When we had to perform a repair we had a similar approach to what you did Kurtis with 1 or 2 notable changes. We had temp sticks that we could touch to the part, and when they melted, we knew the part was at temp. We also periodically rechecked to make sure no portion was cooling down too fast during the repair. I think the gas burners are a good idea. However, I think had you spaced them further from the repair area to heat more of the part, it probably would have helped. One more thing we did was to cover the part in very thick welding blankets when we were done, to insulate the part from cooling too fast. I'm sure you've already learned the lessons that come with failed repairs, but that's half the fun, in my opinion. I hope you find this constructive and I still feel like you did good work. Cheers from the Ohio/Michigan line

@bjbeardse 7 месяцев назад

I have seen and HEARD when those couplers crack. Sounds like a pistol!

@ruifilgo 7 месяцев назад

The way i see it is for this dimensions, you need to put the entire cast in a oven to bring all of it to the desired temperature. Come out the oven wrap it up in blankets to preserve temp as mush as possible and repair the cracks. Obviously to work on this amount of steel mass, you need to wear a suit protection, and in final put it back in the oven, equalizing temperature and then do a controlled cooling down. I think it requires special installations. Kurtis is a brave man, a honest one, good for him to be that way with is costumer. This was a great experience. He's young and will continue to gain experience and already has the correct approach to keep growing. Great video.

@davidelliott5843 7 месяцев назад

Can the casing be saved with a new steel insert brazed into the iron?

@artstudio9673 6 месяцев назад

I think those temp indicatores are called pyrometric cones he in USA

@johnhironimus5748 5 месяцев назад

You actully can save it all just follow proper welding procedure time and patience we fix it all

@yepok2957 5 дней назад

I've never seen a safety inspector so excited to go to work. He's a good dog, and thanks to y'all, living a great life. Get some, Homie.

@rnk482 8 месяцев назад

At the beginning of this video I told my girlfriend this guy is nuts for even attempting what he's about to do. I'm sorry for laughing when I heard the crack but I realized that I was right. That is just way too much damage cast-iron to successfully fix. At least with my welding experience. I've been a welder for 18 years and was rooting for you. I was hoping I could learn something from this. What I learned is that cast iron is just as difficult for you as it is for me.

@joelpirela509 8 месяцев назад

Saludos hermano espero te encuentres bien, quería preguntarte si en tu experiencia de 18 años que hubieras hecho tu y que hizo el mal que se pudo haber evitado esa falla tan catastrófica de la carcasa

@davidbastow5629 7 месяцев назад

@@catpartsforyouokay, so to make it not sound like a brag, share some wisdom: do you think any mistakes were made here? Is it a simple case of just not having the right equipment? Any tips for others, or Kurtis in how to have more success in the future? Any thoughts on whether impurities in the casting may have contributed to the problems? Would you have used a puddle/powder torch? Or a different method?

@sampsani 7 месяцев назад

@@catpartsforyou I would think that the freight alone would cost more than a new part locally, if they were to send it from Australia to US and back for repairs.

@shaunkelly9053 7 месяцев назад

@@davidbastow5629just guessing but I’d say the main problem was uneven heating. Kurtis heated it up but h wasn’t able to really make sure it was all the same temperature. And when he started welding that part got much harder then the rest and it started to crack, or make cracks that were already there get worse.

@sjv6598 7 месяцев назад

@@catpartsforyou it’s all well and good telling the world how easy a repair this would be for you but for those with less wisdom than yourself, please enlighten us to what you would have done differently. Otherwise any Tom Dick or Harry could say that they would have fixed it successfully.

@baronclime6423 7 месяцев назад

Cast iron is a pain no matter. Not many out there would show a failed repair. Props to you Kurtis. You told the customer what may happen. It happened and showed the internet how things can go pear shaped.

@tbrowniscool 7 месяцев назад

100% a decent, honest dude. And WE all learnt how hard it is to repair!!!

@randytolle6706 7 месяцев назад

I know welders who have welded engine blocks with NIRod with preheat and post heat that failed and also just quickly welded without cleaning or any prep and some just work out and others don't.

@artstudio9673 6 месяцев назад

I think more than 50% of what we have learned in life came from our fails rather than our wins.......when I am sober tmrw not sure that will be as profound.?..lol 3:13 a.m. in my man cave in PA USA....lol

@andyr3322 4 месяца назад

100% agree! I only found this channel a few days ago and was very impressed with Kurtis's work ethics from the very first video i watched. Even with my limited engineering background i learned VERY early on that CI is a right royal b's****d to deal with( unlike Kurtis i actually like working with CI on my lathe and mill LOL! ) I would hazard a guess that this particular casting came with unwanted stresses in it ,straight from the foundry, i reckon there was a problem with the cooling of the casting right after it was 'de-moulded'@@tbrowniscool

@spudatbattleaxe 7 месяцев назад

Sometimes a bad casting is just a bad casting no matter how much love you put into it. Great video I much enjoyed it

@spudatbattleaxe 7 месяцев назад

@@dekus80 i hear what youre saying but remember the casting was already damaged and stressed before he started working on it. Not that we’ll ever know the cause of the original failure but that definitely plays a large part in it!

@skunked42 2 месяца назад

Really seems to just have been a bad casting from the start. From my limited knowledge casting is kinda dice roll thing. Maybe that one cooled to quickly from the factory. At least it didnt fail in use and take some expensive gearing with it.@@spudatbattleaxe

@Turbo_rito 7 месяцев назад

It's the temperature differential. The entire part needs to be evenly cherry red. A great investment should be a bigass kiln. Place the entire thing in the kiln/oven, spray weld with a larger orifice, higher material volume, and place back in the kiln for reheat. Every cast piece I welded worked a bit better when the whole part was hot AF. You may be able to save the part if you mill out the face to the edges, place the new plate on top and with a bevel. weld it on in sections while the whole housing is hot AF, reheat and then mill/bore out the features that face needs after the cool down. The plate will need to be hot too so there's no major tension when it cools. I fixed a few cast iron outdoor tables, they had this basket weave pattern and it would dissipate heat fast and would explode in a star pattern when the outside perimeter would cool faster and shrink while the inside hub would expand with the weld and destroy the whole thing.

@marvinmarlin9655 8 месяцев назад

Kurtis thanks for showing us things that go wrong. The guy that taught me to weld said that it’s only by understanding why something went wrong that you can learn how to do it right. A mantra I still use today. You both work so hard on getting things right within your relative skill sets that makes every episode a joy to watch, you and Karen deserve every success. Homey’s contributions are also priceless.😂

@szczesiu 7 месяцев назад

He wouldn't if there was no Homey time in it

@lesliewhyte4647 7 месяцев назад

Just another reason why so many people follow every episode of CEE Australia. Thank you Kurtis for putting that episode on here. The way you explain every detail as you work is amazing.

@wastafus 7 месяцев назад

Good effort Curtis, Too bad the casting cracked, “there’s cast iron for ya. May I suggest that you take the Barbecue plan to the next level. You may want to heat the whole housing with charcoal a “bonfire” to heat the whole casting so the process may have a higher probability of success. The cooldown is also easier to manage as you can allow the the heat to die down slowly. It will be a hot workplace though!

@MattysWorkshop 8 месяцев назад

😊

@CuttingEdgeEngineering 8 месяцев назад

👊😎

@ezrhino1803 8 месяцев назад

ive been with the channel since the beginning. What strikes me is the willingness to admit defeat in certain instances and in doing so make it a victory for the channel. The explanations, the work, the videography, the editing, the comic relief, all of it come together to make the channel truly the special thing it is. Why there are not a couple of million subs defies logic. Certainly deserving more as it is one of the best channels on youtube. Cheers from Texas.........

@CuttingEdgeEngineering 8 месяцев назад

hey mate we know you've been here for the long haul and really appreciate it!!

@johngibson3837 7 месяцев назад

Hey up mate I think this is probably your best video yet,really enjoyed it, has the 40 year man made a comment on this would be interesting, anyway love the honesty and all the best to you three

@Peter-gi3re 7 месяцев назад

In due time Kurtis will have millions of subs. His channel is growing at a good pace. Many of his videos should be shown in technical schools. We all learn so much from watching his content. I still can’t fathom how Kurtis has so much knowledge at his age.

@MrCarlHaas 7 месяцев назад

accepting your own mistake is what the professionalism is

@johnspathonis1078 7 месяцев назад

Hi Curtis I would recommend that you try Eutectic electrodes for cast iron. Cast iron electrides are usually 100% nickel or a Ni/Fe blend. They are a bit expensive but are good quality. The advantage of using an electric arc process over oxy is that there is much less heat involved. While you have the broken casting it may be a good learning expereience to trial some electrode repairs. I have persponally used (sucessfully) Eutectic electrodes to repair a cast iron frame on a tractor about 48 yrears ago. So Eutectic has been around for a while. Also progressive heating in small steps then wrapping in an insulating blenket may help to give a slow uniform temperature rise especially with a large 3 dimensional complicated casting.. Also wrapping in a blanket after doing the work will ensure a slow cool. Differential expansion and contraction is the killer with cast iron. Even with an electrode repair, preheating the job is still requird. Cheers.

@RazorEye 8 месяцев назад

What I love about your channel is that you aren't only showing the "best case scenarios" of everything, you show all the low points as well. The fact that you didn't charge for a repair that didn't work out speaks tremendously for your character and that you never want to compromise on what your work means to your customers. Nothing but respect to Kurtis, Karen and everyone's favorite safety officer.

@charlesangell_bulmtl 7 месяцев назад

Unfortunately, the world is full of hungry 'operators' In litigious US of A, some might sue if they thought they'd MAKE a buck That the customer accepted the risk speaks of both their characters...👍

@not2zen 7 месяцев назад

Here in the US of A we are full of money grubbers, too many people have no integrity anymore. It’s a breath of fresh air to deal with people who have integrity. Look a man in the eye and shake his hand and that should be golden, but unfortunately nowadays often times when you turn and walk away you get a knife in your back. You my friend are a perfect example of integrity, that’s why I enjoy watching your content, cheers to you and your wonderful lady and of course the side kick.

@DRV-mt5dd 7 месяцев назад

The most important thing was that you clearly talked it through with your customer regarding expectations before you started!! I know you didn't charge, but I hope your customer takes care of you of you some for the efforts knowing it might not work. Only fair.

@thepagan5432 8 месяцев назад

We made thousands of gearboxes over the years and thankfully never suffered too much from cracking. One type was prone to cracks so we redesigned the area and changed to SG iron, problem solved. Rarely have I seen breaks like yours, but there were one or two that were caused by rapid stopping and as the gearbox was under load the area around the output shaft would exhibit cracks more often through the dowel pin location holes and also on a few of the bolt holes. Very interesting post which exhibited the problems that can arise with cast iron repairs. Thanks for posting Kurtis, Karen & Homey 👍

@jonginder5494 2 месяца назад

I’m so impressed how deep and broad Kurtis skills are. He’s a top notch boiler maker, machinist, sculptor etc etc. Great talent and hats off to those who taught him him his skills.

@jonginder5494 2 месяца назад

And his materials knowledge and domain knowledge. Brilliant.

@floydlenz2280 7 месяцев назад

WOW ! You are human.. We all try and fail sometimes.. If you haven't failed , you are not trying the hard things in life.. Great vid Amigo.

@ZeroneAngel 8 месяцев назад

Showed this video to a mate of mine that works in the on site workshop. We had exactly the same issue with one of our 980's. He said that it apparently is a material quality issue on some Cat machines from a few years ago. I have no idea if that is the case, but he's been in the business for over 45 years and usually knows what he's talking about.

@alexanderSydneyOz 8 месяцев назад

It certainly looks suspiciously like there is a fundamental problem with the entire casting.

@CuttingEdgeEngineering 8 месяцев назад

Hey mate thanks for the comment, it could very well be 👍

@ironsidestwo 8 месяцев назад

Not sure any amount of skill could have saved this casing, kudos to CEE for even attempting it and showing us the results, failure is a learning process just as important as success👍

@briannicholson714 7 месяцев назад

Welding cast iron is hot, sweaty and stressful job. You usually get it because a replacement is bloody expensive or unobtainable. Welded quite a lot with oxy/acet and ferrite rod. As with electrode, fixing a lug or a straight across crack is fine, but come to welding a hole in the middle of something, it never ends well. And all that sweat and gas come to nothing. But we always seem to try again. Thanks for all your cracking videos. Brian from Lancashire England

@Meowschitz 7 месяцев назад

To all you people saying this is a failure it is not. This is a learning opportunity for these two. When you say failure you immediately admit defeat and do not ever do that just learning the few mistakes you made. Like i said the few mistakes once again I would love to work with you because you learn and remember from every job you do.

@fountainvalley100 7 месяцев назад

You guys should do a field trip to the cast iron guy and interview him. It would be interesting to hear his thoughts on cast iron.

@shamildaghestani 7 месяцев назад

As an engineer this kind of content, that shows you a failure of a project is so valuable and is the closest thing you can learn that is closest to actual experience. Thank you. ❤

@jamestaylor8509 7 месяцев назад

I love your interactions with the birds.

@davidabaxter4424 7 месяцев назад

The filming and editing are amazing.

@dubyahtuff 8 месяцев назад

Bravo to whomever cleaned it before sending it to you!

@Ordog213 8 месяцев назад

There was Water/Fluid in the crack, so most likely they cleaned it in a big heating pool with cleaning solution, soaked that fu**er over night before inspection

@markfryer9880 8 месяцев назад

Yes, they should get some credit, because that part was bound to be absolutely filthy and yet it arrived in presentable condition.

@helplmchoking 8 месяцев назад

And props to their maintenance guys for spotting those cracks when they were still so small, there'd be a good bit of damage if the casting had broken fully while in use

@ctdieselnut 8 месяцев назад

@@helplmchoking oil leak they were trying to fix was a smoking gun. But still, your right.

@Torta--is--PLUR 8 месяцев назад

Steam blast cabinet similar to what they clean engine blocks in

@Joffetorp 8 месяцев назад

I love that you show failed attempts too😊

@jaywethington1934 7 месяцев назад

Im impressed with people that put failures out for everyone to see and learn from. Its better for us to see the problems before we go spend $1000s in matls, time and energy to just ruin someone's equipment. And more respect for not charging them. There are a lot of shops that would still charge them for it, at least here in the states. I'm a subscriber for good.

@jeetenzhurlollz8387 7 месяцев назад

i am a software developper, but i think without computers, society will still be ok. but without machinists, we go back to 1700. big respect to you all out there. you make the world function.

@gearjamor 8 месяцев назад

I can only wonder and fear what Homey would do to a pile of unprotected Christmas presents!

@calebb5106 8 месяцев назад

the only violence Homie ever commits is against packaging and squeaky toys, and he's getting really good at it

@gearjamor 8 месяцев назад

@@calebb5106 The way the fans love him, he's going to be kept busy. Rubber chickens and pigs ears.. .Yum Yum...nom nom nom.

@logiboy123 8 месяцев назад

Lol

@DaleDix 8 месяцев назад

It would be worth the sacrifice.

@jasonneedham6734 8 месяцев назад

AaaaHhhhm..,....open 'em up 😅😅😅😅😅there

@paulcooper2897 7 месяцев назад

There is a back story to that casting ... Cast Iron tough to work on, but that case has a LOT of stress in it to continue developing new cracks like that. Honestly not sure it would have been repairable, regardless of who was attempting it. And .. Puddle Guns are so much fun! Thanks for sharing 🇨🇦

@DavidD-qr2vn 7 месяцев назад

Yea, I doubt that one went through a proper normalizing (stress relieving heat treat) when it was cast. There was a huge amount of residual stress in that casting. Even if it hadn't cracked while he repaired it my bet is it would have continued to crack in the future.

@Len_M. 7 месяцев назад

I hate cast! The crystalline structure and the junk in the metal is such a pain to work with. All you have to do is grab a piece of cast and light up your tig torch and watch the garbage come up and float in the pool of molten metal.

@MostlyInteresting 7 месяцев назад

Yes... I too suspect that casting was junk from day one. It cracked for no apparent reason. So is as full of stress and and maybe inclusions. I hope CAT did not have that cast in the states, its embarrassing. Should have been warranted out early on.

@andymachala999 7 месяцев назад

The stress was not there to start with (that's what cast means), but high heat in isolated places was never going to work. Not to mention high nickel in spots. Well now we know.

@MrKotBonifacy 7 месяцев назад

_"that case has a LOT of stress in it to continue developing new cracks like that"_ - my thought exactly. Firstly, "original" cracks developing for no apparent reasons, right at stress rising/ concentrating points (bolt holes around a large openings), from (presumably) regular work induced stresses and vibrations - like, "whisky tango foxtrot?" - and then the enormous cracks developing while the case cooled down... This case must have been a piece of junk from the day it left the foundry, just waiting to show its true colours. The bottom crack, the last one, wasn't in any way connected to those at bolt holes, yet it developed "just like that", and not when heating the case, but during the cooling. I remember watching Keith Rucker building up, by spray welding, damaged ways in a steam loco stoker (made of cast iron, obviously) and it was all smooth, easy-peasy even though the walls of that stoker seem to be much thicker. (You can watch it here, "Steam Locomotive Stoker Engine Restoration - Part 7: Spray Weld Buildup of Cross Head Slides", ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-5kcTeyw2As0.html.)

@dennisbrooks4742 7 месяцев назад

It's nice to see that with all your experience that things don't always pan out & you're prepared to show it.

@Turboy65 7 месяцев назад

This is actually the best video to demonstrate the problems with welding cast iron that I've ever seen. It's highly educational and should be shown in its entireity to EVERY welding class.

@TheRealSebastian583 8 месяцев назад

NOT ALL HEROS WEAR CAPES! I can hardly wait for Mavel to knock on you door for the next MCU Blockbuster movie: “The Machinist vs. The Giggler”. Karen in the main role AND behind the camera. Kurtis quickly welding up a cage that even the Hulk can’t break. Homie makes friends with Groot and has his mobile toilet with him all the time. Disney getting their lawyers ready to sue them for the appearance of George and all his friends snuggling with The Giggler - who would have made a great Disney Princess. At the end Kurtis and Karen walking into the sunset and the train finally f*cks off. What an epic movie :) As usual - I just love everything about your work and Karens videography! Friday 9:00am in Germany, Coffee ready, time blocked in my calendar and constantly refreshing YT for the newest CEE video to appear. Now weekend is about to start. You three are a true gem on the internet. Keep going mate!

@CuttingEdgeEngineering 8 месяцев назад

hahaha that's a brilliant comment, we can see how it might go like that 😂👍

@donniecardwell3786 7 месяцев назад

Nothing wrong with failure as long as you learn something from the experience . In my opinion Curtis has an overwhelming amount of knowledge and experience in his craft ,work ethic and passion to do the job correctly and methodically. Thank you Kaeren for your great contribution and skill as a videographer to bring these valuable work experiences to your followers and Curtis for sharing his vast knowledge .

@Vinlyguyx420x 7 месяцев назад

So much respect (the deepest definition of that word) for Kurtis showing that things don’t always work out the way you planned and how to handle them like a true professional. All you can do is try.

@spkrman15 7 месяцев назад

Love the honesty and transparency. Much respect

@ToolTimeToday 8 месяцев назад

WoW!! Not everything can go to plan and i for one appreciate that you uploaded this video due to the nature of how the end result showed itself. I for one got more insight to just how difficult cast iron can be to work on. Loved the video.

@marklowe330 8 месяцев назад

I would say that casting had problems from the foundery. Like maybe the cast iron was cooling off too fast when it was poured. Great attempt at repairing it. Thank for you time. And Karen's hard work too.

@daborg015 7 месяцев назад

It shows how honest he is. I really like watching him and his wife’s videos. Greetings from the Netherlands ❤

@user-oq8ym2fs3p 28 дней назад

You’re a good man. You live with honor and respect. Thank your parents and wife!!!! Stay true to yourself your work ethics are second to none!

@scottbarron1427 8 месяцев назад

A true master craftsman does exactly what you did at the beginning of this video. Always give the nod to the guy that's better than you. Then to promote a GoFund me for a competitor. Pure class.

@bobhudson6659 8 месяцев назад

Matty is a good friend of theirs.

@mattyb7736 8 месяцев назад

I see Homey is putting his Australia Post parcel sorting skills to good use.

@michaelmcclown5593 8 месяцев назад

Hey come on as an ex Aust Post employee I absolutely resemble that comment.

@tetedur377 8 месяцев назад

I think it's the same the world over, actually. Except here in the States, the postal workers steal checks out of envelopes, "wash" them, changing the recipient and the amounts, depending on what the check was written for.

@michael931 8 месяцев назад

Could get a job with UPS but he would have to destroy them a little better.

@nipponsuxs 8 месяцев назад

@@michaelmcclown5593it wouldnt be an Ozzy post delivery if those boxes didnt came looking like a football 😊

@retsamyar 7 месяцев назад

@@tetedur377 lol take a tour a big USPS sorting building. You would believe the security in those places... while they might have some bad apples slip through they are hardly what you appear to imagine. They employ security like a prison or money printing operation.

@jkent9915 2 месяца назад

I only come here for the “right-o”s, the dog, and the crazy welding and machining.

@killbill_1967 7 месяцев назад

Great video. Much respect to you Kurtis for putting this video out and showing that it doesn’t always work out the way you would like it to. I’m always impressed by your skills and even though this one didn’t work out, your reputation and integrity remains intact. Keep up the good work 👍

@rogerwhittle2078 8 месяцев назад

Even with a massive bust like that, it wasn't exactly a failure. You called it correctly going in, you did everything possible to obviate all the problems, but in the end it was cast iron that simply overwhelmed you. A great shame because you deserved success with all the prep and, at least, your customer can see precisely what happened and when. They can't accuse you of not trying! Great vlog, as usual and your wild bird audience seems to be getting bigger. You'd think all the noises, movements (and smells probably) would scare them off permanently, yet they keep coming back for the treats. Nice one.

@MattysWorkshop 8 месяцев назад

Gday Kurtis and Karen, thank you for everything you guys have done for use, this video shows exactly how things can turn to crap in a hurry and definitely important to show on camera to proof it does happen from time to time, almost makes you think the casting was crook from factory with the first crack appearing for no reason, great video mate, have a awesome weekend, cheers

@Murphyslawfarm 8 месяцев назад

G'day Matty hoping you are doing ok mate

@jaquigreenlees 8 месяцев назад

The casting being extra dirty cast iron and bad from the factory was my thoughts as well.

@markfryer9880 8 месяцев назад

Hey Matty, thinking of you mate! Be prepared for a roller coaster ride of emotions during this event. Wash off the bad ones and keep positive! Mark from Melbourne Australia

@CuttingEdgeEngineering 8 месяцев назад

Hey Matty we'll be there for you all the way! This was definitely a good character building exercise 😂 I think Kurtis handled it well, I was pissed off after getting that far to have it crack was so frustrating. We did notice that there were no cracks in the repaired zones so it probably would've been successful if the other areas didn't crack.

@markfryer9880 8 месяцев назад

I was having my suspicions about the quality of the original casting and just maybe some of the treatment that machine had experienced for those cracks to develop? We will never know exactly what caused the cracks, but it might explain why the machine was up for sale? Mark from Melbourne Australia

@heathicusmaximus8170 7 месяцев назад

I really appreciate you showing that even with careful planning and good work, a repair may still fail and that it's super important to notify the customer of the risks. Love your channel.

@Mk6Escort-RS2000 7 месяцев назад

Well done you for having a go. Every job has its challenges and you faced this one honorably.

@jayperion5712 7 месяцев назад

I got to give always credit to Kurtis for attempting repairs on new parts , nothing always goes as planned but there's always that chance something can go wrong...what you learn afterwards makes you better at what you do and were all right there with you helping you along....and Karen, also thank you for taking us along with Kurtis and our favorite 4 legged safety officer!

@pickelsvonbrine 7 месяцев назад

Advising clients and honoring your work is a true sign of a pro. You are a honorable man Kurtis. Professional and fair.

@davidwillmore 7 месяцев назад

The outtakes are wonderful! Great direction, Karen!

@EricAnderson-AKA-Norwedsh 7 месяцев назад

I'm never disappointed with the videos from Curtis and Karen. There is always something new; a technique, a repair, or in this case, a failure that reveals their true, honest, character. It's no wonder that they're so busy. I look forward to next week's video.

@Sam-Diamantidis 8 месяцев назад

Before even going through the video ... You supporting a human going through a tough battle with cancer is absolutely AWESOME ... Oh and by the way ... keep them videos coming ... 💪💪💪

@CuttingEdgeEngineering 8 месяцев назад

Matty deserves it, and honestly feels like the least we could do for our good mate!

@benwinter2420 8 месяцев назад

Lots of turbo cancers recent in Oz thanks to the eugenics pointy thing in arm

@armageddontools 8 месяцев назад

@@benwinter2420 You think thats bad ? Australia is huge i live in a small village in Croatia with barely 1100 people and 2 people from my family died of cancer, i know 5 neighbours that have it or had some type of cancer,and there is plenty of people in village that die or get sick.Worst thing is everyone is clueless whats causing it since we dont have big industry nearby or badly polluted air. I am afraid i will have to run away or i might be next . . .but i dont have money to do it.

@gav2759 8 месяцев назад

It would have been easy to ditch this footage and show yet another successful repair, but things aren't like that in the real world. Thanks for posting this. The housing could be repurposed as a chew toy for Homeless, but I don't fancy it's chances there either.

@davidduffy9806 7 месяцев назад

Mate, you're a genuine, authenitic hero. I'm in awe of your achievements

@FrankTheTank417 7 месяцев назад

We can’t win them all. Don’t beat yourself up. It was awesome just watching and learning about what needs to be done. Great video.

@ScottMinns 8 месяцев назад

The camera work, editing, and story telling are just keep getting better. I learn stuff that'll never use in my real life, but Kurtis just keeps teachin ! Years of experience being passed on. Thanks for another great video.

@Watchyn_Yarwood 8 месяцев назад

Agree 100% !!!!

@johncarey9149 8 месяцев назад

Good on 'ya for showing that things don't always work perfectly in RU-vid land. It takes a lot of character to show when things don't go to plan, but in my mind it's really valuable to see the pitfalls. Good on 'ya

@nickclarke587 7 месяцев назад

Hi Kurtis. My father used to repair fractured castings without heat, a process that stitches the cracks together by a process pioneered by Metalock. He worked for them for 40 years and I'm sure they have an Australian division..

@eddiekulp1241 6 месяцев назад

It's called JB weld 😂

@Eric-gi9kg 7 месяцев назад

The sound those birds make are quite amazing. You may be in for the whole family feeding

@zestoslife 8 месяцев назад

I wonder if the impurities are related to probability of cracking. I understood how heat expansion but never thought that it would cause that many cracks. Was amazed at how many appeared, and where they appeared. Was expecting more in the corners. I guess a massive oven would have been helpful, along with a bulk load of sand to hold the temp high for the body while it was being fixed. Given how difficult this would be, wonder how the other guy does things of this size.

@markfryer9880 8 месяцев назад

Even with the sand you have to be careful, ensuring that it is clean and dry. Cast Iron is a nightmare. 😢

@IamJimhunder 8 месяцев назад

I really appreciate your work and props to you for showing that not all repairs go as planned! Keep up the good work mate!

@lukearcher886 7 месяцев назад

An honest look at the work of a talented craftsman. You make your hard job, look fun and easy. Thank You guys for sharing it with us!

@ecalzo 7 месяцев назад

you're incredible Man .. the amount of knowledge you have and how professional and humble you are... WOW. .. Hi from Italy .. would love to shake your hand thou

@andrewbegg9944 7 месяцев назад

It's not failure, it's a learning opportunity, Kurtis, we love your therapy sessions, you talk with authority and confidence during the work and you've got a dog. As an engineer, I love watching what you do, it's the best therapy I've found. Keep at Dr. Kurtis ❤

@willtricks9432 8 месяцев назад

Honesty and customer relations is your reputation. Your rep is great. Cheers

@arniebriscoe2978 7 месяцев назад

Truly an honorable gentleman and businessman.!

@joshfenton5522 7 месяцев назад

Such an awesome channel. Kurtis so talented and yet so humble. Very refreshing.

@n4leqonthego852 8 месяцев назад

What I love about this channel is that Kurtis is willing to show projects that don't go to plan, thanks for the videos.

@_Juan_Pierre_ 8 месяцев назад

Started watching your videos about 2 months ago, I'm now caught up on everything. The work you do is amazing and the manner in which you deliver it to your audience is superb! Cheers from South Africa! 🍻

@CuttingEdgeEngineering 8 месяцев назад

hey mate welcome to the channel, glad you're enjoying the videos!

@pacificcoastpiper3949 8 месяцев назад

@@CuttingEdgeEngineeringthat loud PONG from the housing even made me pucker

@falcon8553 7 месяцев назад

My most profound and greatest respect Kurtis. Truly enjoy watching your videos.

@philthewiz 8 месяцев назад

Hi Curtis, you can’t win them all. CI is very difficult to repair by any method. Thanks for showing a job that did not go to plan. Always enjoy your vids. Thanks from the UK.

@jonnekjonneksson 7 месяцев назад

Congratulations for publishing the failures also, honesty and professionalism are two rare values today, you represent both at the highest level.

@ianbates1312 7 месяцев назад

I’m really impressed with this video and the effort you put in to save the casting. You recognised the fact that it may not be a success from the get go. There are lots of machine repair shops that wouldn’t even entertain it because of cast iron’s notoriety ❤

@ned_mograph5957 7 месяцев назад

very very cool of you to show the successes and the failures. transparency is great

@danielcarter305 8 месяцев назад

LOL...Not only is Karen a grate editor, and cameraman, she is also a very demanding director too! Love ya Karen thank you!

@CuttingEdgeEngineering 8 месяцев назад

hahaa thanks Daniel 😜

@ctdieselnut 8 месяцев назад

Editing is always on point. Naturally, i credit the dog. J/k. thank you

@97PercentFire 8 месяцев назад

Absolutely fascinating - didn’t know a fix like this was a thing that could be done! 👍

@haydenc2742 8 месяцев назад

It's not easy...usually the entire part has to be heated to stupid temps...then welded up...then covered up and let cool VERY slowly!

@ctdieselnut 8 месяцев назад

Apparently, it can't! Just joking, he has other videos of doing casting repairs. This one was particularly nasty and complex, you really can't fault him imo.

@mambans 7 месяцев назад

Thanks for also showing the projects that did not go as planned.

@MDAZIM-cm3qq Месяц назад

We are completely impressed by the work done so beautifully

@hot_wheelz 8 месяцев назад

Can't win em all Kurtis. Big props for having the stones to put the jobs that don't go to plan on show for those who want to criticise. IMHO, it just shows that not only are you and excellent machinist and Karen a great videographer and editor, but you've also go the ethics to back your words.

@markdouglas5542 8 месяцев назад

So soul destroying when it doesn’t go to plan Kurtis, but you gave it your best shot.

@ctdieselnut 8 месяцев назад

Having a waiver setup with the customer is essential for something like this. That softens the blow a bit. If you think you may fail, it's best to have that mutual understanding established ahead of time.

@willmeldrum4583 7 месяцев назад

Always happy when a new video arrives

@wilddog1985 7 месяцев назад

Absolute legend. Phenomenal attempt and unrivaled honesty in the business.

@normanbuchanan9710 7 месяцев назад

that was commendable in so many ways, the fact you admitted your lack of experience with that particular part, the fact you took it on to try and help the costumer, the fact you showed all the difficulties while working it and the finale (the failure of the part to hold up) mad respect to and the Lady for another fantastic video.

@Bodie2020 7 месяцев назад

Prime example of a good craftsman. He educates and shows what really happens in the real world and that repairs aren’t always successful. Thank you for sharing.

@elljay4587 7 месяцев назад

Not only are you a very talented metal worker, you are a shrewd business man.

@mikebellamy4760 7 месяцев назад

Super respect for showing us when it goes wrong. You put up a good fight there Kurtis!

@dscroop 8 месяцев назад

I love Friday's :D new CEE! My 4 yo boy loves to sit and watch as well, I just stop it before the bloopers :)

@CuttingEdgeEngineering 8 месяцев назад

Awesome mate so glad you and your little dude can watch together, that's a big reason why we cut swearing out of the main video 😄👍

@raymondrobbins9495 8 месяцев назад

1st another great video from CEE. I have never seen you fail at a repair so that was interesting. It sucks that you couldn't repair the housing. Thank you for showing us that not every job can be repaired and that you are human and do fail at some repairs. Good on ya Kurtis and Karen. Cant wait to see what you do next week.

@KBorham 7 месяцев назад

The casting failed, not the human. Had to clarify…..

@raymondrobbins9495 7 месяцев назад

@@KBorham yeah i understand that my wording could of been better. i was getting excited seeing that he was doing so well until i heard the crack happen. Shows how brittle cast iron actually is.