Craftsman Floor Jack Rebuild-Help

[Jeepster04]

I'm replacing the u-seal seal for the 3rd time in my old 2 ton aluminum Craftsman floor jack. I bought this jack in the 90's when I was a kid at a place that sold Sears returns. Going there was pretty fun when I was a kid, I bought a good bit of Craftsman stuff and still have all of it.

Anyway, the jack has unfortunately been replaced with a.... Harbor Freight Daytona.... but I would love to keep this thing working since its so light and theres the whole sentimental aspect. It's also easy to grab and throw in the trunk if I'm working on something away from home.

The issue is, it has slots cut in the bore that relieves the pressure when its at max height and the seals from HCRC are evidently not up to the task. These slots are cutting the seals nearly immediately. The 2nd time I replaced it, it lasted for years b/c I made sure I didn't max it out, until I did...

Think I can smooth out these slots someway? Any reason why I couldn't buy some carbide bits and smooth out the edges? Maybe there is a better seal available somewhere? The original seal lasted a 25+ years, so idk why these cant. I tried emailing HCRC to see what they had to say and they ignored the question and sent me a link for a new u-seal at almost $30...

 

[ajchien]

My eyes are squinting... Are those left over machining burrs at the edges of some of the slots? I would certainly smooth those burrs and sharp edges out. And, yeah, I think it’s wise to avoid maxing out the height on jacks that have that kind of design to prevent over extension.