Welding Aluminum Bracket for Ancient Dump Truck
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  1. #1
    Join Date
    Mar 2014
    Location
    Troy MI
    Posts
    100

    Welding Aluminum Bracket for Ancient Dump Truck

    During disassembly by mistake my customer broke off the ear of the bracket, because he didn't see the last bolt. After I cleaned up the casting I noticed that there was a second crack. I grooved out the 2nd crack from both sides for 100% penetration and filled it up with weld. When I was grinding the broken off ear, the carbide burr caught it and threw it from the vise, never to be found again, so I had to make a new one. Fortunately I had the welding and machining fixture done by that time, so I new where to locate it. The following pictures document my progress.

    1. Cracked Bracket
    2. Cracked in two places
    3. Outside of 2nd crack
    4. Inside of 2nd crack
    5. Making welding and machining fixture
    Attached Images Attached Images      
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport
    Lincoln LE 31 MP & Lincoln 210 MP

  2. #2
    Join Date
    Mar 2014
    Location
    Troy MI
    Posts
    100

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Here are some more pictures.

    6. Bracket mounted to fixture
    7. Making new ear
    8. Carbide burr to bevel casting
    9. Standoff for welding ear
    10. Spotfacing excess weld
    Attached Images Attached Images      
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport
    Lincoln LE 31 MP & Lincoln 210 MP

  3. #3
    Join Date
    Mar 2014
    Location
    Troy MI
    Posts
    100

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    And here are the last two.
    I will try to get a picture of the truck when I drop the repaired bracket off.

    11. Bracket welded and machined
    12. Close up of welds
    Attached Images Attached Images   
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport
    Lincoln LE 31 MP & Lincoln 210 MP

  4. #4
    Join Date
    Jun 2012
    Location
    Bemidji MN
    Posts
    13,207

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Looks like an excellent job
    Dave J.

    Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~

    Airco 300 - Syncro 350
    Invertec v250-s
    Thermal Arc 161 and 300
    MM210
    Dialarc
    Tried being normal once, didn't take....I think it was a Tuesday.

  5. #5
    Join Date
    Oct 2015
    Posts
    73

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Great project! Looks like you did a good thorough repair.
    Thanks for posting the pics and showing the steps that you took.

  6. #6
    Join Date
    Jul 2011
    Location
    Bossier Parish La.
    Posts
    5,048

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    I thought those ancient dump trucks were built from stone, not aluminum. How were you able to weld the new aluminum pieces to the old stone parts?

  7. #7
    Join Date
    May 2018
    Location
    Land of the Toxic Avenger
    Posts
    210

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Nice job. Where does that bracket mount?
    T man.


    15 + years working for myself, and by golly, I still don't know what I want to do when I grow up.

  8. #8
    Join Date
    Mar 2014
    Location
    Troy MI
    Posts
    100

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Quote Originally Posted by Bistineau View Post
    I thought those ancient dump trucks were built from stone, not aluminum. How were you able to weld the new aluminum pieces to the old stone parts?
    Attached is a picture of the dump truck and the engine compartment showing where the bracket mounts.

    13. Old truck
    14. Bracket in engine compartment

    Quote Originally Posted by T man View Post
    Nice job. Where does that bracket mount?
    Attached Images Attached Images   
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport
    Lincoln LE 31 MP & Lincoln 210 MP

  9. #9
    Join Date
    Aug 2008
    Posts
    10,976

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Ancient???????????????????

    WTF????????????????????????

    Late 80's to mid 90's. I certainly don't think that's ancient. Holy Christ.

    That "ancient" thing will be on the road long after this new iron gives up the ghost.
    "Any day above ground is a good day"

    http://www.farmersamm.com/

  10. #10
    Join Date
    Apr 2013
    Posts
    62

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Lol........ 1990 is ancient !

    Quote Originally Posted by farmersamm View Post
    Ancient???????????????????

    WTF????????????????????????

    Late 80's to mid 90's. I certainly don't think that's ancient. Holy Christ.

    That "ancient" thing will be on the road long after this new iron gives up the ghost.

  11. #11
    Join Date
    Aug 2008
    Posts
    10,976

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Godam throw away society.

    Ancient truck. 94' model. Paid for...……………….265,000 miles ago, and 24yrs ago.

    Well PICS AREN'T WORKING AGAIN. I pretty well have had it with this site. I'm on my own site, or SFT. Later doods
    "Any day above ground is a good day"

    http://www.farmersamm.com/

  12. #12
    Join Date
    Jul 2011
    Location
    Bossier Parish La.
    Posts
    5,048

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Quote Originally Posted by prconnection View Post
    Lol........ 1990 is ancient !
    That's just starting to get broke in good. When you said ancient, I thought you meant like maybe a 1915 Mack or something. What, are you like 10 years old or something?

  13. #13
    Join Date
    Mar 2014
    Location
    Troy MI
    Posts
    100

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    My customer said that the bracket was for an “ancient dump truck”.
    He showed me the truck when I returned the repaired bracket.
    I just weld stuff together, what do I know?
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport
    Lincoln LE 31 MP & Lincoln 210 MP

  14. #14
    Join Date
    May 2018
    Location
    Land of the Toxic Avenger
    Posts
    210

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Quote Originally Posted by Don52 View Post
    My customer said that the bracket was for an “ancient dump truck”.
    He showed me the truck when I returned the repaired bracket.
    I just weld stuff together, what do I know?
    How to make a nice repair.... I would say.


    Now how about the missing head on the engine? Sumbuddy. Stold it...

    Lol
    T man.


    15 + years working for myself, and by golly, I still don't know what I want to do when I grow up.

  15. #15
    Join Date
    Mar 2011
    Location
    Western Washington
    Posts
    358

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Nice work Don52


    Always a pleasure to see a repair done good, clean and precise.

  16. #16
    Join Date
    Apr 2013
    Posts
    62

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Quote Originally Posted by Don52 View Post
    My customer said that the bracket was for an “ancient dump truck”.
    He showed me the truck when I returned the repaired bracket.
    I just weld stuff together, what do I know?
    Way to make the old guys on here feel ancient Don!........lol I love it

  17. #17
    Join Date
    Mar 2014
    Location
    Troy MI
    Posts
    100

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    The owner was in his early 40’s, so it was ancient to him.
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport
    Lincoln LE 31 MP & Lincoln 210 MP

  18. #18
    Join Date
    Aug 2012
    Posts
    31

    Re: Welding Aluminum Bracket for Ancient Dump Truck

    Quote Originally Posted by Don52 View Post
    The owner was in his early 40’s, so it was ancient to him.
    He would have been in High School

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