INDUSTRIAL ITEM REPAIRS

ALL PICTURES ARE CLICKABLE

We cater to all industrial repairs, including shafts, brackets, motor bearing sleeving, gears, broken mechanisms, etc. We can also replicate unavailable parts. For breakdowns, we offer an overnight repair turnaround time where possible.

Here we have an example of an emergency repair. The shaft runs 24/7 in a machine, being driven by the gears. Over time, the shaft developed wear, which resulted in the key breaking and the gears slipping. The quickest and most cost effective repair option was to reduce the shaft size beyond the wear and sleeve the gears. We welded the sleeves into the gears and machined them to fit the new shaft's diameter. We repaired these items overnight. Downtime was 12 hours against four weeks for importing the OEM part.

Here we have a stainless steel, plastic bag handle cutter which had cracked welds. We did the repair using stainless steel TIG welding.

Above we have an aluminium come along that the client had damaged by overloading it. The overload caused the one side of the mechanism to tear off, while the other side was severely damaged. We cut both sides off below the shaft holes and rebuilt them using aluminium TIG welding. Hand contouring the resulting welds, reformed the original shape. In the bottom picture, we had not yet restored the original holes.

Here, we have an aluminium hydraulic crimper head with a crack that developed because of excessive pressure. We machined out one side of the head along the crack to around 60% depth. Then we filled up the machined out groove utilising Aluminium TIG welding. We used the same procedure on the other side, resulting in a 100% thickness weld.

Here, we have an aluminium hydraulic valve block with a crack that developed between the large threaded hole and the top of the block. The crack is so fine that it is very hard to see. We machined out a large area around and through the crack to enable us to fill the void with weld metal and seal the leak.

Above you can see an aluminium impeller housing that was damaged during use. This repair was tricky and required us to match the original housing's internal radius and height. We beveled both parts and made a jig to secure the piece in place before TIG welding the aluminium together.

Here we have an aluminium motor end cover that houses one of the two motor bearings. The clients have broken a mounting lug off the cover during assembly. We prepared the parts for welding, and aluminium TIG welded them back together.

Here, we have an industrial stainless steel clutch assembly that required a small modification. We were required to weld the inner stainless tube to the outer cover. Stainless steel TIG welding was used to achieve this.

In the above pictures, we have another aluminium impeller housing with a broken mounting lug. This lug had completely disintegrated, and we rebuilt it with layered aluminium TIG welding. We machined the top surface flat, re-instated the hole, and tapped the required thread into it.

Here we have a broken cast iron industrial motor mount which came in for repairs. Welding cast iron is never a sure thing and depends on the quality of the casting material and the amount of crud in the pores. Here, we brazed the bracket together using a silicon bronze filler rod. The resultant joint is as strong as the original cast iron and adheres completely to the parent cast iron.

Above, we have a worn bearing seat in a cast iron motor end cover. To repair this damage is multi stepped, with the first step being the boring of the cast iron seat wider to accept a steel sleeve. The setup for this is challenging because the new machined bore needs to align with the original bore axis, which is now worn and not reliable to establish a center. Here, we used the small hole behind the seat as this was untouched. We machined a steel sleeve on the lathe to a press fit and installed it into the new seat. The entire assembly was then re-machined to slide fit the bearing diameter.

In the pictures above, we are machining the motor shaft to fit the new impeller inside diameter. This is a simple job if you have an undamaged shaft center at the end opposite the chuck. If this is not the case, a new centre has to be established using some other existing feature as a reference. Once an acceptable centre reference is located, we can carry on with the turning of the motor shaft.

Here, we had to repair a crack in the slide component of a decommissioned weapon. We did this using aluminium TIG welding.

Above we have a miniature exhaust for a model airplane which had broken in an unintended rough landing. We machined a new exhaust pipe and built up the receiver for it using aluminium TIG welding. Hand shaping and polishing completed the job.

Above, we show a magnesium gripper rod used in the printing industry. The client damaged this unit when debris entered the mechanism, causing a portion of the gripper structure to break off. We built up the broken area with magnesium TIG welding and then milled the surfaces back to factory specifications.