Making the NEW Cylinder Barrel! | Hitachi ZX470 Cylinder Rebuild | Part 2
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- čas přidán 14. 09. 2023
- We've got the damaged hydraulic cylinder disassembled now it's time to make the new barrel! This video is Part 2 of rebuilding a stick (dipper arm) cylinder off a Hitachi ZX470 excavator. In this video we show the complete process of making a new cylinder barrel including machining apart the old barrel before machining and welding together the new barrel. We also show fitting on the head flange using an interference fit, pressing out the old bushings with our 150T hydraulic press and honing out the heat affected zone in the new barrel! Stay tuned for the next video of this cylinder rebuild where we make the new piston and reassemble the cylinder!
MISSED PART 1?! Watch it here: • It's STUCK! Can We Get...
In this video we are using:
- Hafco TM-26120G Centre Lathe
- MetalMaster HPM-150T Hydraulic press
- 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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Hello Queensland........thanks for another great video, cheers from the Other 'Sunshine State' Paul
787
You spun the barrel in the lathe, you didn't flip it.
Suggestion for video: “Karen’s comments” - every time Karen says “mint” or the like.
“Karen‘s sniggering at double entendres of the metalworking world” eg “relief nipples”
Have an awesome weekend guys, cheers for the great content.
As long as I got here so early tonight, I'll say this. As an engineer, I can't begin to tell you how much I respect Curtis' knowledge and capabilities. I don't give that out lightly. It's a rarity, and you're quite the rare breed. These videos are the highlight of my week. Thanks.
hey mate thanks very much I appreciate that 👍
@Cutting Edge Engineering Australia I got up in the middle of the night to watch this. LOL Cheers.
*Kurtis
Agreed, as someone who has an engineering background I've got a lot of respect for Kurtis. He is rare breed indeed.
Always a pleasure to watch a tremendously skilled and educated worker. Incredible work.
Сколько смотрю, каждый раз удивляюсь количеству инструментов и станков у этого человека. И внимательность к деталям при работе тоже вызывает восхищение.
My dad was a carpenter for 45 years before he retired and his shop had sparrows that would roost there in spring. They built nest and along a wall in the back of the shop and every year they would raise a new clutch of young. My dad cut a hole on the door for them to fly in and in and out of, and they would zip in and out all day bringing in food for their babies.
I only remembered that when I saw him feeding those birds. Good childhood memory, thanks buddy.
Sparrows are great birds
These barrel rebuilds are just captivating to me. No matter how many you do, I will still watch every one of them. They are similar but each has a bit of a difference. Such as this one having a cast flange. Great to watch!
So enlightening to ger such comment from all over earth 🌍
Kurtis properly loading an old cannon is the epitome of this episode!!! 😁
that was my initial thought, too.
@raudi42same.
same over here
He should check into the laws down under and make a small gauge cannon doesn't need to fire shot just straight black powder do it for the GIGGLES
This is the best machining channel on CZcams, no contest. Thank you Curtis and Karen!!!
Wow, thanks mate we appreciate it!
@Cutting Edge Engineering AustraliaI really look forward to your videos every week, and enjoy every minute. I really like how you speed up sections of video so we get to see all the steps but it doesn't take so long. Thank you!
I agree strongly! More importantly, it's the only channel with Homie! ❤
Totally agree. Great stuff, great information and excellent video work. They are a super pair. So many channels where people love their own voice and just blab away. And no 'hidden' product placements either. Just strait up factual information. Love them both
Agreed 👍
Really strange. I was going ask if Karen ever catches "mistakes" or "something's just not right", and there she goes and does it! 🙂
Watching you tap the bearing off the cylinder after machining away the PERFECT amount of metal has convinced me that you are actually a wizard. Your secret is out and your clever rouse has been foiled.
Cutting edge engineering. Home to a superb Engineer, a brilliant film producer, a multi-talented four wheeled drive parcel examiner, birds, helicopters and a plethora of tools and equipment. Excellent combination, not to be found anywhere else in the world and addictingly entertaining too. Cheers guys.
I definitely like the way you work Curtis. I'm sure you're plenty strong enough to lift a lot of those parts but you're smart enough to use the crane and the forklift. I was a mason for 20+ years. I've done more than my share of heavy lifting over the years. Now that I'm older my back is paying a heavy price for all the hard work. Trust me my friend your back will thank you when you're older. You young guys can learn a lot from Curtis so pay attention.👍🏻
As a heavy vehicle mechanic myself, i totally agree, back when i was doing my apprenticeship little was said about OH&S, steel cap boots and overalls was about it. Curtis is a smart lad he will do well.
@fred zephire Exactly. I agree. We didn't even wear hard hats unless the general contractor required them. A lot of things have changed since my days as a mason.
Brilliant advice for young people in school. That kind of advice is something that definitely needs to be made each morning like the pledge of allegigance
Maybe you get tired hearing the same old stuff, but the quality of engineering and video recording/editing is superb. Real professional stuff which, even as a layman with no actual need to know this stuff, is a real pleasure to watch. Great job, both.
Karen is filming and giggling, Curtis is working with a straight cap, Homeless is ripping apart packages and George is screaming, singing or whatever these sounds are called.
I suppose it's a normal Friday at the Gold Coast and i love it 🙂
Karen is filming which is also working, otherwise no CZcams film. So, thanks Karen👍👍👍👍
@Erik Barsingerhorn which, not witch!
@Robert Jung Corrected👀😅
Witch wurd wuz speled rong,eye dead ant notis!
@Peter Smart 🤣🤣🤣
Your attention to detail is beyond reproach. Always a blast to watch.
Just got to say that these videos are truly amazing the professionalism, attention to detail, and the knowledge and ability that is on display here is not to be taken lightly! Just so awesome to witness a true Craftsman, rebuilding and refurbishing things instead of just swapping parts!
Like the homemade lifting bracket for the tailstock chuck. Simple and effective.
Kurtis, you make everything appear really easy - a true Craftsman indeed - and a great pleasure to watch!
Those button inserts are beasts. I love this content but i don't know why, I don't have any experience or dealing with engineering for work or hobby yet every week Im glued to the videos. Thanks for the time and effort you take to make this content its really interesting and you guys have great chemistry and of course homeless is awesome. All the best from the UK
Love the addition of the clock, shows how long in real time things take to do, great addition idea.
Kurtis, I always give you praise because your workmanship and craftsmanship are second to none. But Karen, your editing and camerawork are getting amazing!! Your switches between not only shots but themes as well is flawless! Let’s be honest also, you make Kurtis sound like a Nobel laureate and we all know words are not his forte. I’ve never had any problems or issues watching your videos but they’re now so seamless it’s like watching a high dollar production! You mam, may have missed your calling.
O sorriso da Karen, o canto do passaro e o profissionalsmo do torneiro tudo é lindo neste video
Birdies! I didn't know George sings for his food 😊 Geez you both have skills most of us could never dream of having. The details in the filmed content all the way through to the knowledge and honesty shared by Kurtis.. Keep up the good work...
So much in this 'simple' rebuild... thanks for taking us through it with you. I appreciate the explanations along the way; had no idea about Hitachi designing their cylinders with relief and sacrificial metal at the stationary end...it makes so much sense! Today's vid is a tour d'force!
Hi Curtis, Karen. Have you ever imagined that your videos will be watched all over the world? Stunning work as always, and I love your little bird ZOO, lol :)
hey mate, we honestly never expected our channel to grow as big as it has and to have so many supporters around the world!
You two a wonderful job making videos. I enjoy them and I’m a woodcarver thanks
24:15 - 26:05 was some great capture and editing. I guess Kurtis did something too. 😅 Amazing stuff. You both always start my Fridays with a smile, thanks. An example of professionalism every week.
PS: My goof's get excited hearing Homeless open packages. It makes their Friday morning a treat as well!
As a younger tradesman, your videos are always inspiring and relaxing. The way you handle jobs with ease and confidence really makes me feel good. Having a positive attitude about a shit situation, or getting a really good job done well, is so satisfying. Thanks, mate.
J'attendais avec impatience la deuxième vidéo, regardé avec un immense plaisir, toutes mes félicitations, car en France il n'y a pas beaucoup d'artisan de cette qualité !!
Cutting edge engineering you are getting replies from all over earth 🌍
unreal workmanship and the wife filming never miss a show so good to watch keep it up cheers.
That was another great video. I love seeing that big hone in action and Karin was quite enamoured with George and his cohorts. We're really looking forward to seeing the creation of the piston and final assembly. Best wishes to you three from Bruce, Karin, Halgrim and Bella. We wish you a pleasant and joyful weekend.
thankyou Karen and Curtis for our weekly lesson in barrel making and also having a nature element, feeding the wild birds and learning about their different calls and eating habits. you guys are a great channel to watch. awesome job as usual Curtis your the best machinist i know by far. there is no limit to what you can do. take care guys.
He sounded like a gate that needed lubricating at one point!
You all have created quite a monster with all the Georges flying around these days. Take care and have a great weekend!
Worse yet... They don't even TASTE that good, and they're bloody finicky to pluck too!
@Trevor van Bremen Clay wrap and bake whole (well, maybe gut it first). All the feathers will come off, hopefully, with the clay.
(Do not do this with the Georges. Eating birds, yes. Georges, no).
Soon the magpies will take over and it will just be a magpie channel with humans in the background at most
I'm a carpenter master and wood is my favorite material but I love to see every Friday your videos. I'm impressed over your knowledge and skills and want to say thank you to Karen and you for your informative and interesting videos.👍
Best greetings from Norway ❄️❄️❄️
Curtis is AMAZING, I’m not even an engineer, or machinist (something I’ve always wanted to do) but I can see that this is the guy I would want to learn from ……TRUE professional!
I’m addicted to these videos. I watch them as soon as they’re released.
Watching those birds sing to you was a real treat. I love how much you value the animals, like that time you rescued that lizard that was stuck in a machine.
Back at Disney, watching Kurtis. Still an amazing craftsman. Thanks for posting this . Steve Also, thanks to Karen for making the video so easy to watch.
It so satisfying watching professionals doing their job properly and with Pride!! I would be your customer if I lived in Australia!! All the best !! Legends as usual!! Homie 😎 is really cool!!!
Gday Kurtis and Karen, sounds like hitachi have put thought into there cylinders with the simple things like a centre, absolutely awesome to see the hone doing it’s job again and it certainly wouldn’t be hard to over cut each side of the effected area, George and his mate put on a good song this week to, great job mate and thank you, have a great weekend, cheers
👍
Curtis, your engineering skills are second only to your potential to become a deadpan stand up comedian. Given the entertainment at the end of your demonstration during the out takes. Can’t wait for the piston episode…and the out takes. Well done . !!! T’owd Homeless needs to become your apprentice. Thanks for the demonstration 😊
Damn, he makes the tricky stuff look easy. Every time I think "but but but how's he gonna ...." and I only have to wait and all is explained and shown. Great stuff, thanks!
I work a late/swing shift so it’s always nice to watch someone else work when I get home, LOL. I don’t know why I think that’s relaxing but it is and there is no comparison to all the other content on CZcams, your unique content is in my wheel house as to what I work on all day and I enjoy expanding my knowledge. Hard to find people these days that put workmanship, craftsmanship and pride in their work and I appreciate the effort you all make and share with others. Big thumbs up from the STATES 🇺🇸
Ive been working a dupont swing shift 12hrs for just over 20 years and I tell the new guys youll never get used to it only build a tolerance for it. whew!
Love the Butcher Birds. I get woken by their calls every morning.
Mine sound the same but they play their own unique tune.
Love the machining as well. 🤠
Cool two handed turning. Most people don’t appreciate how difficult that is.
Never normally comment on here, but thank you curtis and the giggling camera girl for making countless hours of entertainment. Really makes my day when I see a fresh upload, love the content and think I have finally watched nearly every video you have put out! Keep up the good work
Curtis, you truly know your stuff. Thank you for the great videos. I am only a hobby machinist and your videos are very much appreciated. Thank you sir.
I just love the swarf from the button inserts, it's kinda pretty. But I also like the long pig-tails from the parting tool as well. How long to clean up after a job like this? And another great video is done, well done to both of you! Excellent editing as always Karen.
I have no clue why I find these video's so fascinating, but I do. Looking at the number of subs, I'm not the only one. The attention to detail in both the process and the camera work is just the best out there. Keep up the fine work!!
Another GREAT video from the CEE team. I was quite impressed that Karen knew the tool centre height was wrong. One of the first things I learnt at TAFE 45 years ago when doing the machining section of my fitting and turning course.
Great work, it is so satisfying watching you complete all the various stages of this process🚁🧐🇦🇺
I'm impressed at how you set up your operations so that you obtain the required concentricity using a three-jaw chuck, and in a way that avoids having to dial-in a four-jaw chuck. You also know where that's important and where it's not. My compliments.
Glad to see that compound at 30°. I enjoy watching you do steady rest work. When i was working at my last job i did all the steady rest work. I've made custom cylinders from scrach with honed tube. Made many a rod and piston. 30 years machining and 20 of it programing large lathes. So its very enjoyable and satisfying to watch you work. With your precision and attention to detail. Thanks for you time and Karen's time and effort too. I know she has a tough job making you look good. Lol...your faithful watcher, the disabled machinist.
White men in 2023 are no longer in a position to benefit from overt self-deprecation. Allow me to observe that Curtis distinguishes himself by his fine work ethic and entrepreneurial spirit. His modest and devoted wife captures his very best moments on camera.
Thank you for not putting in any corny music as filler in your videos. Great editing
Karen, this is one of your best edited vids. So much to cover and produce but done in a way which was easy to watch and understand. Well done !
Thank you 🥰
Nice job, as always Curtis is an expert and Karen is the best cameraman
It's such a pleasure to watch you, Karen and Kurtis and your, respectively, excellent work.
Man I have been waiting ALL DAY to watch this! It's corporate tax filing deadline today in the US and I work in pension administration so I spent all day crunching numbers. Time to relax with Kurtis, Karen, and Homey! Thanks for giving me something to look forward to!
Great job guys !! I just love the quality you put into your work !! I really enjoy the outtakes and Homie he is the greatest !! I cant wait for the making of the new Piston !!👍👍
Thanks for sharing this insightful video series. If you ever tire of doing you would make an excellent instructor and educator. Thanks for sharing this series. Wishing you both and your furry kid another blessed week filled with gentle seasonally appropriate weather and restful evenings together. Peace
Another great job ! And Karen's editing and videography is going all pro now . :)
Kurt, I am very impressed with the variation in thickness of the barrels walls. When you make the cut on the lathe, we can see that the eccentricity is absurd. I notice how your welding (done manually) is much superior to original welds of these barrels, which are done through automated processes. Your welding is very well distributed, with constant thickness. Congratulations on your skill. Greetings from Brazil.
Brazil is well represented as intelligent people such as your self enlighten the entire world 🌎
It makes me angry. He says that 30 minutes of welding was needed at 20:00, but he only weld for a few seconds in the video! Nobody can weld that fast
And there is NO FOOTAGE of the welding at 30:08 …. How do we know if he even did the welding???
Love it when you work the feed manually with the crank handle and feel your way along, sculpting the weld surface.
I have no idea what is happening most of the time but it sure is awesome to watch you guys work!
Curtis is so good and inspiring at his job that he makes me want to switch careers so I can do this full time.
Those welds look absolutely perfect!
Loved the editing on this video Karen! You’re a true professional! And great job as always Kurtis. Love to see you do your thing. My dad used to be a machinist but never got to see him work, so great to see this.
its getting there. soon you will be able to re assemble the parts. You make it look easy. Good video Kurtis. Its good when you have the tools to complete this kind of work. Hope to see the next part next week. Look forward to that video.
Outstanding work as always. Y'all make great videos, Thank you.
Thank you for including the wonderful magpies! And the real-time clock behind Kurtis on the welds. Rocking!
Awesome as Always.. Love these barrel repairs... Is there ever a time where the cylinders have to be certified pressure tested before installation?
Thank you for another great video. I'm a 75-year old retired machinist and welder, and still learn something from you on about very one of these.
Brilliant as usual guys you are my guilty pleasure every Friday morning here in the UK. Looking forward to seeing the finished product on the next instalment 😀👍🏻👍🏻
Hi, from Sacramento, CA USA, love all the vids, incredible videography and incredible attention to detail. Keep it coming and more puppy shots please . 😊
I'm west of you in Sonoma County
Hey mate thanks so much for watching & commenting!
I’m in Woodland
Should I put on "It's a Small World" for us? 😀
Great work, well thought out and executed. Impressive to watch. Thanks for sharing.
Love your channel. Wishing you guys much success. Thank you for the content you guys put out in your videos. I can imagine that it's not easy at times but they're great.
I feel like Kurtis is slowly getting closer to building a cannon if he has not built one already.
Well done, great work, video editing is fantastic, and the outtakes are the icing on the cake. Looking forward to the piston machining video.
Great video and words to live by… Always keep an eye on your stones.
Good job, glad to see the birds still around, my wife and I live on the side of a mountain in a forest. We have so many birds around which we feed even got birds which sing through the night too. The honing machine is awesome and must be very handy not having to send work out. Sometimes the weld prep took longer than the welding, but we always made sure it was done right. Great post. Thanks Kurtis, Karen and of course Homey 👍
Your videos are a tremendous stress reducer! Fascinating! Greetings from Massachusetts, USA.
Kurtis you're a wizard with that lathe. I have learned so much from your videos over the years. Thank you man.
Thanks to Karen for her great video recording n editing skills, especially the bloopers lol + big thanks for Homie doing his usual duties around the workshop n opening his surprise toys, and as always a pleasure watching someone like Curtis who takes great pride in his machining and welding. As I have said once before being a boilermaker/welder once upon a time myself I can honestly say that Curtis is on par with his welding skills as I used to be, as I used to take pride in all my work n loved to do the odd bit of lathe work. My favorite welding was Aluminum + Stainless Tig + heavy plate stick n mig welding. Watching these videos puts me in calm tranquil place lol. Almost forgot to add love the birds in the vids also.
Another nice bit of engineering excellence! Thanks to to both of you I enjoy seeing Homey and George too!
That new honing machine awesome Kurtis, the whole job description has to be precise, old school mate , 👌. Karen's filming excellent 😊 . Homeys trying to get his ball😂❤. Baby butchers hatching soon😂. Had my Cutting Edge Engineering fix with a couple of coldies , good stuff guy's 👌🙏.
Thanks! You two never disappoint! Wondering if there is a video of you discussing how you got your start in the business, any training or schooling you may have received. You don’t just wake up one day and start doing this kind of refurb work.
Would be great content
Your experience shows in little things like machining the steady bands down to the same diameter so you don't need to reset the steady when flipping the cylinder. A random guy like me might just machine them until clean and then lose time re-centering for a different diameter.
Watching Curtis work is one of the most relaxing things to watch on CZcams. 🎉
Another great vid ! Always interesting and they highlight how important a forklift is ! A very versatile machine !
👍👍👍👍👍👍👍👍
Love seeing the honing machine getting some work. Each job pays it off hopefully.
Those birds sound really neat! We don't have anything even close to that sound here in Oregon. Their behavior is very similar to our blue and grey jaybirds, but that SOUND!!!! Really neat to hear that. It speaks highly of you both that they trust you that much. Homey is cute and funny, but these birds are the high point for me. That and of course watching you craft metal into high quality components for some very big machines!
Noice! Another awesome episode packed with great machining content.
Shop-made Q-tips are the best! You'll never have clogged ears again, after a single use 😂
Your videos are the highlight of the week! You've absolutely perfected the mix of teaching and entertaining👌
I love your work! Your wife does great camera and editing! I think homie was wondering where his package was and went to search it out 😂 love the birds !
You know that your a CEE "junky" when you know beforehand which tool he's going to use before he sets up.. Love your channel Curtis.. never miss an episode..
I have a question. If it's Kurtis and Karen, why is it not Kutting Edge Engineering?
I agree with Karen, that barrel is mint. I love the behind the camera commentary. You two have an excellent relationship doing this work. Love the style. The outtakes at the end are 100%.
Hitachi always comes in clutch with regards to fixing/remanufacturing their tools! All of the big Hitachi drills I reman have alignment guides for bushings cast into the housing so you don't need fancy jigs like most others. The motors also don't need to be pressed apart. It's neat to see that they carry that same design language into bigger parts too!
Nice job. Love how spot on your work is to spec. Great video!!
Another brilliant video from CEE waited a week for part two,but well worth it.
SUGGESTION: Before you go to sand blasting, nock off most of the flat/accesible areas with belt sander(or grinder sander if dust is not an issue when you outside). That will save you loads time
Another awesome Friday morning watching Curtis and Karen do all the hard work. Your videos are very enjoyable and educational.
Again brilliant engineering. Loved you finishing stone hone blending into main cylinder. Such a fine tolerance you achieve. If you have time ... can a tolerance fit be so close that lubricant will stop the mating of 2 parts? I worked in a PNG airline supply my office immediately adjacent to the engine shop assembling Continental and Lycoming engines and that story went around...
It always amazes me that there is such precision, yet a lot of the processes are blindly machining/honing, then checking manually, little bit more, checking, little bit more, done, with 0.005mm precision 😀