Caster repair.

[Turbo1002]

Had this automobile jack for some years now. The other day as I was rolling it the caster fell apart. Went on the internet to find a replacement - discontinued. This was an expensive jack and I don't want to see it go because of this reason.
I have access to a mig welder but need an idea how to repair this? The slot where the E clip sits was designed very weak and the metal has cracked. Was thinking of cutting the broken area off and welding a washer there but as you can see there the caster moves up and down the plunger will hit the weld if I put it on the inside. If I put the weld on the outside the race for the bearings will hit the weld. Need some advice please. The caster part number is G63200-006. Such a horrible design for an expensive jack. The clip does nothing when the weight of the automobile sits on it , all it does is keep the assembly from falling apart when the jack is lifted. Thank you

 

[joe49]

Tap it back in place, grove out the crack, and take it to get it TIG welded.

 

[Turbo1002]

That spot where the e clip goes is also where the crack is. The metal is really thin there. Do you think after the Tig weld the e clip will go back on?

 

[gorilla]

Weld up the groove perhaps add some metal above the groove turn to proper diameter and re machine the groove.

 

[Ole Slewfoot]

Replace the E clip with a couple tack welds and call it done.

 

[Turbo1002]

gorilla that is a true repair but I don't have a lathe. Just a guy with a grinder and mig.
Ole Slewfoot looks like that will be my last resort.

 

[joe49]

Replace the E clip with a couple tack welds and call it done.

direct drive like he said will be the easy way.
Or you could go out and buy a file to clean up the groove.

 

[matt_i]

If the shaft for the wheel itself was removable from the yoke, I like the idea of grinding the thin edge off flush, and then plug weld a thick washer of appropriate ID to re-form the top of the ring-groove, but stronger. However that axle shaft looks peened/riveted and would be another repair or modification. As mentioned above, a lathe would be quite handy for fixing this.

On edit, I see what I think is a socket head screw in there, which potentially precludes plug welding...

One issue that I feel needs to be addressed is possible over-width of the groove relative to the ring itself. For example if the E ring is loose (in width) there will be point loading if the yoke ***** relative to the shaft as its moved.

 

[Turbo1002]

Yes you are correct there is a screw inside. Caster has a spring inside so it can move up and down. You are also correct about the width of the groove. It has become very loose because of the the width. The wheel is riveted on the yoke and I prefer not to take it off because then I would be altering the load bearing portion of the caster although the wheel is a little offset to the side. Might be able to get a welder in there.

 

[4xdog]

If it's an inherent weak link, how long before the next one goes?

Maybe replace both front casters with a more conventional bolt-on design? That way they'd match, and I doubt the spring loaded feature is that useful. Might take some modification of the hole with a sleeve to fit a thinner shaft, but that's probably doable.

 

[rsanter]

How about looking at newer jacks to see if you can make wheels from them work?

If it was me I would machine an all new piece, but I read you don’t have a lathe.
Can you have one machined? Is there a local adult school you could take a class or pay a student to do it? Local community college?
Fellow GJ ember you can bribe with food and alcohol?

 

[Turbo1002]

I appreciate all the help very much. Some day I might invest in a lathe. Many years back I made a few pieces even took a class. For now I used a step bit to open up a washer. Took a few pictures. Did not weld it yet, not 100 percent sure if I want to go this route yet.
Out of curiosity, to purchase a small lathe what would be the start up cost? Used would be fine. Where to start?

 

[whateg01]

Check you inbox.

As far as a small lathe goes, sky is the limit. You can find usable lathes for a few hundred. In general, like other tools, if a new import/junk is available for X dollars, I prefer to spend that X dollars on a used old iron machine. What part of the country are you in?

Dave

 

[Turbo1002]

Thank you all for the help. This is my repair, know it is not pretty but it should hold. Welded the notch where the clip was to reinforce the cracked area. Then tacked the washer on top.

 

[kbs2244]

I go on the side that says replace the pair.

http://www.castersupply.com/index.htm