Four wheeler gearbox repair
#1
I did this a while back, it is a gear box or transfer case or something like that for an ATV of a friend of mine, who is rough on things lol. You can see the lug cracked, and a chunk missing.
[Image: th_2011-10-24_17-25-32_754.jpg]
[Image: 2011-10-24_17-25-55_276.jpg]
So I decided to make a new lug and cut the remains of the old one off. I had to fabricate a fixture to hold the lug in the right place to weld it.
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Made the lug.
[Image: 2011-11-02_11-43-37_668.jpg]
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Put a radius on the lug to fit the gear box
[Image: 2011-11-02_14-50-16_745.jpg]
monkers, proud to be a member of MetalworkingFun since Nov 2012.
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#2
Then had to cut the old crap off and clean up the gear box and fit the lug.
[Image: 2011-11-02_14-48-45_228.jpg]
This is how I held it in the vise to do the lug removal surgery
[Image: 2011-11-02_14-27-03_718.jpg]
Then I threw some bird ***** at it with the spool gun, and added a pad in a weak area
[Image: 2011-11-03_15-23-44_45.jpg]
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After welding I started cleaning up and blending with a flap wheel.
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Another good before shot
[Image: 2011-10-24_17-25-55_276.jpg]
It came out ok, he was happy with it and its still holding lol
Thanks for looking. My TIG is a Squarewave 175 and I wasnt sure if it had the oomph to do it so I used a spool gun I have at work, and did it on my lunch breaks.
Craig
monkers, proud to be a member of MetalworkingFun since Nov 2012.
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#3
Nice repair Smiley-eatdrink004Smiley-eatdrink004Smiley-eatdrink004
It would have taken a big TIG set to weld that up
The wire feed is not as prity as a Tig but the welds look plenty strong enough Smiley-dancenanaSmiley-dancenanaSmiley-dancenana
John
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#4
Thank you! Its still holding, think its been a year or so lol
monkers, proud to be a member of MetalworkingFun since Nov 2012.
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#5
(12-01-2012, 05:04 PM)monkers Wrote: Thank you! Its still holding, think its been a year or so lol

The time and care you have shown in the jig to set it all up is the impresive partWorthyWorthy
John
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#6
Good repair, thanks for posting this.

(Nice "YOST" vise!!)
sasquatch, proud to be a member of MetalworkingFun since Jul 2012.
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#7
Quote:The time and care you have shown in the jig to set it all up is the impresive partWorthyWorthy
John

Thank you! Yes, getting it right is important;) better to spend an extra few moments with the set up then trying to figure out how to make it fit when its wrong :)
monkers, proud to be a member of MetalworkingFun since Nov 2012.
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#8
(12-01-2012, 05:40 PM)sasquatch Wrote: Good repair, thanks for posting this.

(Nice "YOST" vise!!)

Thank you for the kind words. The vice is very nice, use it all the time :)
monkers, proud to be a member of MetalworkingFun since Nov 2012.
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#9
Fantastic repair Craig,
Thanks for the post.
Jerry.
ETC57, proud to be a member of MetalworkingFun Forum since Feb 2012.
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#10
(12-01-2012, 10:52 PM)ETC57 Wrote: Fantastic repair Craig,
Thanks for the post.
Jerry.

Thank you Jerry, glad I could share a little bit. I really enjoy reading everyones posts and checking out their work.
monkers, proud to be a member of MetalworkingFun since Nov 2012.
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