Making a BIG Hydraulic Cylinder Rod & Eye | Part 2

This video is part 2 of a job we did to make a new BIG hydraulic rod and eye for a Hitachi EX1200-6 Excavator bucket cylinder. The rod has a lot of scratches and the eye is completely torn off the rod and has fatigue so we are making a whole new cylinder rod and eye. This shows the step by step process to make the new cylinder rod including machining and welding. We start with a 170mm diameter piece of MnVS6 induction hardened chrome bar and turn it into the hydraulic cylinder rod before fitting and welding on the new eye that we made in Part 1! First we rough machine down one end of the rod before welding silicon bronze on the cushion. Once it’s cooled we continue machining the rod in the lathe by turning down the silicon bronze and finish machining the end for the piston and nut. We cut a 3mm thread pitch external thread for the nut before flipping the rod to machine the other end. We machine a spigot to fit the rod eye and a taper for weld prep before fitting and tack welding the new rod eye in position. The eye is welded on using metal cored wire before cryo freeze shrink fitting the new bushing using liquid nitrogen. We finish the job by cleaning, wrapping and strapping the new rod and send it on it’s way to the customer.

In this video we are using:
- TM-26120G Centre Lathe
- WIA 500i Weldmatic welder

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Our channel is all about showing you real life machining work from our workshop on the Gold Coast Australia. We specialize in manual machining, hydraulic repairs and heavy fabrication for the earth moving, mining and civil construction industries. So if you're a machinist that wants to see some big gear in action be sure to subscribe to our channel right now. We upload new videos every week that show lathe machining, milling, welding and all the good stuff that comes from a machining workshop. If that sounds like something that you would enjoy seeing, then make sure to join us by subscribing!

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[CuttingEdgeEngineering]

Hey viewers thanks for watching Part 2 of making the new EX1200 cylinder rod & eye! What was your favourite part of the job? Let us know in the comments 😎👍
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[MrWalleyeCrazy]

About 4 yrs ago I had an accident that left me with a serious brain injury. It ended my career as a machinist. I watch these videos and it reminds me of the fun I had taking metal stock and turning it into tools and industrial parts. I might not be able to do the job anymore, but this channel is lot of fun to watch and learn. The short breaks with your dog are a great. Thank you Kurtis for publishing all these videos. An old duffer like me really enjoys watching the process.

[PetesNikon]

I really appreciate that you subtitle information about tool inserts, speeds and welder settings, it really shows you respect us and provides interest as to what is going on. Thanks for speeding up some of the repetitive and boring turning activity. Your quick introduction is quite adequate. This is in contrast to other YouTubers who will not quit talking.

[humancattoy]

I really don't have a favorite part. The entire process is so satisfying. This is my relaxation.

[caspermaul]

Kurtis, Your attention to even the smallest details does not go unnoticed. It's a pleasure watching "zero compromises" craftsman in action.
Greetings from Denmark

[eldorado]

It's not only the fabrication artistry, but also the deep knowledge of how these components are used - and what can contribute to their longevity. I have no idea how expensive it would be to buy an OEM replacement, but I am under the impression the CEE replacement is better than original.

I also don't know how Kurtis does all this work without talking to himself. He never speaks unless a specific point requires narration. I would go nuts keeping to myself like that! 🤣

Fascinating stuff.

[mark]

Mrs. K “I am not here to help, I am here to mock”! You do great work Kurtis.

[patduffy]

Class job again Kurtis 👏. Not only the craftsmanship, but the videos are edited brilliantly. The close-ups, the fast-forwards, the clips of the safety officer etc etc.
Well done to you both.

[jeffpaggett]

This series, his approach could/should be used to teach youth on care and attention, pride in work, accuracy, pure skill and customer service.

[oldmanuserphan]

As a former cargo van courier I really appreciate that you secure the item to the skid. Too many times I got things like that forked in that forced me to do a lot more lashing with the straps than I normally did. My fav was them wanting to load a 500lb steel ring into the van with no skid under it. I was like, "um no. You're not gonna fuck up my cargo bed with your forks. Put it on a pallet jackass"

[steveascension]

If you own machinery in Australia, it's a no-brainer & cheaper to get this skilled Aussie to repair your machinery parts. The only mistake he could make is not passing on his skills to others. In his videos, he illustrates what can be achieved through experience and bloody hard work. In my past working years, I saw men using similar but antiquated machines in very large power plant machine shops. When I went with my Dad to watch a ship being launched he worked on as a boilermaker at the old Newcastle State Dockyard, I remember seeing gigantic lathes, borers, and shapers being used for shipbuilding. Watching Kurtis makes me feel young again.

[garytompkins]

I was a Cat field mechanic and assembled and installed parts such as you do but NEVER saw anything done as well as you create. Your skills and craftsmanship are old world perfection. The videography is also top notch, add the pup and the outtakes, well the most enjoyable video I have seen in a long time. Thanks from an old USA mechanic for putting this on.

[josemanon]

Hi friend. There are "many" best part I prefer; the atention to detail, the multi-task perfection, the fact it seems you never hurry or nervous because you always know-how, etc. But the best is the humour and human side, and of course the "team work" . I value also the endless hours editing video. Thank you all.

[Noswolf]

turn around on 48 hours is damn near perfection. great work you do mate! 10/10

[ihorkoval]

It’s even hard to believe that one person can do so many things and at such a high level. Just unbelieveble. The video is also shot by a professional. Thank you.

[johntripp]

This is my third time watching. I go back and watch different episodes but this job has that certain field. Besides I couldn't lift half of your tools. 65 years since I last turned anything but it still fascinates me to watch a maestro at work.

[ShevillMathers]

Ripper, mate, from start to finish.👍🇦🇺🦘🔭 No fancy intro, flashing lights and crap music or a continuous chatter, the doom of so many you tubers, You get right into what we want, we can see what’s happening, you know what you are doing and how to do it. You and your wife score 10/10 every time on machining and video production. Love the ‘shop boss’ too. Just 👍

[alexfunke]

I think that this, part 2, is the most beautiful and elegant project you have shown us! And, as always, congratulations to the cinematographer! Thank you. Bravo!

[rickypoindexter]

Awesome video series. People like you, the things you make and fix, plays a big part in making this big world go round. Not to mention we get to watch ripper after ripper of high quality videos. Thanks for taking the time and energy to make these videos. All the best from the USA.

[A_friend_of_Aristotle]

At 2:00 and within 27 seconds Kurtis serves up the perfect justification for his business and an eloquent expression of the free enterprise spirit: I can do it cheaper and faster. This is the spirit that creates value for trade, and is the best justification for living in a community of like minded and productive people.

As someone who grew up in a tiny rural farming community in the USA but now lives in a giant city, I can say without hesitation that this is the kind of man I would be proud to have as a neighbor and as a friend. Such people seem to become more scarce as you move closer to larger population centers and I think this is an absolute shame. People in big cities seem to have no sense of their own value, nor do they take pride in the value they do create. They also have no sense of how they should treat other people. There are advantages to city life, but they are becoming more and more of an occasional treat amongst bitter fruit.

I do not miss the rural setting I grew up in, but I do miss the character of its people. Good luck to you and your wife, Kurtis...you are the salt of the earth.