Welding hydraulic ram rod eyes

[m_c]

Are ram rod eyes welded on using standard MIG welding wire, or something stronger?

I'm having problems getting the correct steering ram rods for the forklift rebuild, and I just want the thing rebuild so I can get the axle out the shed.
The rods the supplier thought it was, although the rod length/diameter/thread is correct, the eyes are too big, and use a larger bushing.
The rods with the correct sized eyes/bushes, the rod is too big a diameter.

So to get the thing done, I was going to chop the eyes of the original bent rods, the wrong eyes of the new rods, and weld the old eyes onto the new rods, but given there's only an inch diameter worth of weld, it has me wondering about strength...

 

[Kram]

The rods with the correct sized eyes/bushes, the rod is too big a diameter.

Turn them to size?

 

[pressbrake1]

Normal Mig wire unless your unsure of grade then stainless wire

 

[m_c]

Turn them to size?

All 18" of precision ground/polished diameter?

 

[m_c]

Normal Mig wire unless your unsure of grade then stainless wire

Hmm.
Never even thought they might be stainless!
Although the eyes definitely aren't stainless, and the welds on the new rods don't look stainless.

I'll try sticking a magnet on the rods tomorrow, and see if it sticks.

 

[Kram]

Sorry I misread and didnt see it was hydrualic rods

 

[pressbrake1]

Hmm.
Never even thought they might be stainless!
Although the eyes definitely aren't stainless, and the welds on the new rods don't look stainless.

I'll try sticking a magnet on the rods tomorrow, and see if it sticks.

Sorry what I meant was if your unsure of what grade of steel the rod is made from stainless wire has dissimilar welding advantages

 

[m_c]

Sorry what I meant was if your unsure of what grade of steel the rod is made from stainless wire has dissimilar welding advantages

I'll admit I'm aware of the dissimilar issues, but it's not something I've really had to worry about before.

I might get some stainless wire to remove any doubt.
Any recommendations on what grade of wire?

 

[frank horton]

if I understand this right
can't u press out the larger bushing and turn an adaptor to fit urs, smaller bushing on the new rod.....
photo's might heelp....is there enough room for larger eye's to work on the axle........
also there lots of dif suppliers like tractor / digger, they may have something different.....
what about going with used rams....

 

[Agroshield]

...can't u press out the larger bushing

The bushing would never be a problem. It is the external dimensions of a larger eye that would be the challenge - taller and they won't fit into the clevis; fatter and there will not be clearance.

Cutting Edge on YT do a lot of this work so it is worth reviewing what they do. In particular, on the bigger ones, it looks like they are manufactured with a small boss on the ram and a small hole in the eye so everything assembles concentrically. That means chopping off the eyes on the new rams with a hacksaw might not be the best move. If you do everything in a lathe, everything is concentric, the faces are square to the axis and you can put the weld prep on at the same time.

 

[m_c]

The bushing would never be a problem. It is the external dimensions of a larger eye that would be the challenge - taller and they won't fit into the clevis; fatter and there will not be clearance.

Both those problems apply.
Eye is thicker, and although I could machine it down so it would fit, and use a new bushing (both options still use 25mm pins, just the bigger eyes use a thicker bush), I'd be dubious about the amount of material left. I might have another measure, as it could still be an option.

Cutting Edge on YT do a lot of this work so it is worth reviewing what they do. In particular, on the bigger ones, it looks like they are manufactured with a small boss on the ram and a small hole in the eye so everything assembles concentrically. That means chopping off the eyes on the new rams with a hacksaw might not be the best move. If you do everything in a lathe, everything is concentric, the faces are square to the axis and you can put the weld prep on at the same time.

I did wonder if they use a locating boss, but without cutting one up, I wouldn't know.
I'll have a chat with the supplier on Monday before making any decision.

 

[chrismac]

Are ram rod eyes welded on using standard MIG welding wire, or something stronger?

I'm having problems getting the correct steering ram rods for the forklift rebuild, and I just want the thing rebuild so I can get the axle out the shed.
The rods the supplier thought it was, although the rod length/diameter/thread is correct, the eyes are too big, and use a larger bushing.
The rods with the correct sized eyes/bushes, the rod is too big a diameter.

So to get the thing done, I was going to chop the eyes of the original bent rods, the wrong eyes of the new rods, and weld the old eyes onto the new rods, but given there's only an inch diameter worth of weld, it has me wondering about strength...

I would not worry about the amount of weld, which is one of your concerns, your worried welding the eye/boss on to the end of the ram wont be strong enough. once its on it wont be going anywhere.

 

[nickk]

I do 2-3 of these a year and always use nickel/chrome rods,sometimes there’s a location spigot for alignment,be sure to get a good fitting joint and prepare the ends correctly,never had any of mine come back. Never tried any other weld consumables though.

 

[Turbo]

I used to make up my own bottom arms when I was stock car racing a 205gti.
I would cut the ball joint of a cheaper pug arm and weld it to the gti wishbone.. i would v prep both sides and stick weld with 312 rods. Never had one break in years of hard racing.

 

[Brad93]

Pictures?

GMAW/MIG with standard wire, ER70S-6 will be fine if it only uses 25mm pins.

Prep rod with U groove, eye should rely be doweled / press fit onto/into a corresponding pocket on the rod.

 

[m_c]

Just had another look, and I think machining down the new eye is probably the easiest option.
Thickness wise, the big concern will be that the eye has been bored to the diameter of the rod, in which case there may only be a sliver (or no) metal left where the rod enters it.
Width wise, scalloping a bit out where it might hit the hub carrier (you can just see the area where the paint has been worn off the old rod by dirt build up on the left edge in the photo) is all that would be needed.

Worst case scenario, is I need to cut the eyes off, bore out the old ones, machine the ends of the new rods to fit, and weld them back together, so I've not really got anything to lose by trying to machine the new rods first.

To give an idea of dimensions, the old rod bushing is 30mm OD, whereas the new one is 35mm.
I thought I had taken a photo of the new rod side on, but obviously not.