Rubber Injector..Cooling Chamber..Plunger Repair..

[zapster]

Long involved job here..

3 parts to this assy and all need attention..
The rubber injector is placed in a cooling chamber with seals on each end for sealing in the cold water..
Over time rust and corrosion has wiped out the seal land in the chamber..The seal area on the injector and the plunger has scraped inside the injector and scored the outside finish on the plunger..

Got all that?

OK we will deal with the injector first..

Note the area near the opening where it's "Shiney" on the OD of the tube..
That's the seal area..


This end has no seal area left!


Before I could turn that I needed to make a steady rest area so I could hold it and re-center the end..
So using a brass ring on the threads so they stay nice indicate the tube in as best you can then make your rest area..

The opening end center was right on..

Before flipping it over turn off the other side seal area for your new ring..


Now set up the steady rest and face and re-center the end..




Next!

...zap!

[zapster]

OK all faced and re-centered...


Time for new rings..


Heat..


Install..


Next!

...zap!

[zapster]

Weld in the new rings..







Re-machine to size and this part is finished..




Now on to the chamber..

...zap!

[zapster]

Ahh yes the chamber..


Wiped out end..


This small fitting is in the way..


The tab is in the way..


After grinding off the tab we machine off the old end..


Next!

...zap!

[zapster]

After much math..How much to remove..How much to add..Take into consideration the shrink area..The fitting area..
This is what I ended up with..


New end to install..


Heat..


Install..


Set up positioner again..


One more..

...zap!

[zapster]

Weld in end..


I gave this .010 shrink because the tube is sorta thin and we don't need any leaks..

Monday I will do the other end and address the plunger..

Now it's time!!

...zap!

[Mechtician]

Nice work, as always! I like that welding positioner, what kind is it? I also like the little support rollers under the cooling chamber, I'll be stealing that idea! Keep up the good work

[zapster]

The positioner is a "Aircrafter" by Airco..
Got it on Ebay for cheap$$$

All my wheels are home made..

I have nice rubber ones for when the surface can't be marked up..
Big steel ones...smaller ones 4 different sizes...

VERY handy!

...zap!

[killdozerd11]

You always get the good jobs

Great stuff zap

[kidtigger24]

Originally Posted by zapster

The positioner is a "Aircrafter" by Airco..
Got it on Ebay for cheap$$$

All my wheels are home made..

I have nice rubber ones for when the surface can't be marked up..
Big steel ones...smaller ones 4 different sizes...

VERY handy!

...zap!

How is that positioner holding up anyway? It sounded like it was on it's last legs last time I was up there, and you were only welding 4 link bars, not a heavy piece like that. Time to hit the boss up for a new one. God knows how much money that one made him.

kidtigger24

[bhardy501]

Very cool job. I would love to work on stuff like that, with the right equipment.

[zapster]

Originally Posted by kidtigger24

How is that positioner holding up anyway? It sounded like it was on it's last legs last time I was up there, and you were only welding 4 link bars, not a heavy piece like that. Time to hit the boss up for a new one. God knows how much money that one made him.

kidtigger24

It's just fine..
Needed a tune up.

...zap!

[jdh239]

I never really post on your threads as I am not at your level when it comes to machining and welding, but I find them very admirable. I enjoy your posts. You do great work. Thanks for sharing.

[zapster]

Here are the finish up pics..

I replaced both ends of the chamber..
Set it back up in the lathe and cut new steady rest spots because after heating and welding the old ones run out about .010 and we can't have that..
(.010 on the steady rest just transfers .010 to your finished part..)

It is possible to indicate both old spots in at the same time..
You use the chuck wrench near the chuck and a rubber hammer on the end..



So after that I bored the sleeves out to the proper ID then set up the tooling for cutting the seal groove in..
The groove is .375 wide and .203 deep..
You can't measure inside the groove so you have to rely on your dials and your math..
I just used a custom ground tool by me and did the plunge cut on the groove..
No roughing it out..Just do it..

Pics..
#1..Set back up in the lathe..
#2..New steady rest spots..(Same size!!)
#3..New spots..
#4..Seal groove tool..
#5..Seal groove done..










The plunger was sent out for re-chroming and will be ground when it comes back.

Well that's it for this job..

...zap!