ZJ track bar axle end repair lessons learned

Finally got around to welding on a washer. So far so good but I'm not
really happy with it.

First lesson learned. There are no readily available commercial washers
that are a good fit on a 10mm bolt. 3/8 is tighter on it than 10mm.
9mm won't fit over it, nor will 5/16.

Second lesson learned. The hole is worn out oversized on both ends.
There's only access to weld a washer on the front. The back hole is
still oversized and the washer fix won't work.

Third lesson learned, the thickest washer Fastenal had in stock is still
much thinner than the part being repaired.

Fourth lesson learned. The Harbor Freight 80 amp inverter welder is
completely adequate for this repair--it's quite capable of slagging down
the whole washer if you get careless with it.

Fifth lesson learned. The hole is worn out enough that after the weld
it may be necessary to adjust the position of the axle to get the bolt
back in.

Sixth lesson learned. A Home Depot Workforce 16 ft x 1-1/4 ratchet tie
down does a fine job of adjusting the axle position.

Future action. When the weather warms up I'm going to jack it up, weld
both holes around the rim and redrill for a good fit on the bolt.
That's really the "right" fix.

On 3/11/2012 5:44 PM, J. Clarke wrote:
>
> Finally got around to welding on a washer. So far so good but I'm not
> really happy with it.
>
> First lesson learned. There are no readily available commercial washers
> that are a good fit on a 10mm bolt. 3/8 is tighter on it than 10mm.
> 9mm won't fit over it, nor will 5/16.
>

What about taking some flat steel and drilling the best sized hole?
After all, looks are not critical, and so if it is not quite round on
the outside, no problem right?




--
I'm never going to grow up.

In article >, says...
>
> On 3/11/2012 5:44 PM, J. Clarke wrote:
> >
> > Finally got around to welding on a washer. So far so good but I'm not
> > really happy with it.
> >
> > First lesson learned. There are no readily available commercial washers
> > that are a good fit on a 10mm bolt. 3/8 is tighter on it than 10mm.
> > 9mm won't fit over it, nor will 5/16.
> >
>
> What about taking some flat steel and drilling the best sized hole?
> After all, looks are not critical, and so if it is not quite round on
> the outside, no problem right?

I considered that. People are saying the washer works so I decided to
give it a try.

J. Clarke wrote:

> Future action. When the weather warms up I'm going to jack it up, weld
> both holes around the rim and redrill for a good fit on the bolt.
> That's really the "right" fix.

As my elderly German shop instructor used to say, "der ist rwo vays to do
tings: Right und Offer!"

--
Will Honea

J. Clarke wrote:

> I considered that. People are saying the washer works so I decided to
> give it a try.

Every general purpose washer I've ever seen was pretty mild steel. For what
you're doing, I would prefer 1/8" steel bar stock. Even if you have to
grind the thickness down after welding you get a much better hold plus a
quick spray of water after the weld will quench the piece at least somewhat
for a better temper. On farm equipment (a lot of years back) we tended to
drill out the original hole so that we could weld in an insert as well as
the cap scab then re-drill the whole thing. The idea was to maximize the
bearing area.

--
Will Honea

On 3/12/2012 05:55, PeterD wrote:
> On 3/11/2012 5:44 PM, J. Clarke wrote:
>>
>> Finally got around to welding on a washer. So far so good but I'm not
>> really happy with it.
>>
>> First lesson learned. There are no readily available commercial washers
>> that are a good fit on a 10mm bolt. 3/8 is tighter on it than 10mm.
>> 9mm won't fit over it, nor will 5/16.
>>
>
> What about taking some flat steel and drilling the best sized hole?
> After all, looks are not critical, and so if it is not quite round on
> the outside, no problem right?
>


Dremel hand grinder. And a hunk of appropriate steel.