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"New" Merrill Bros. Vise

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Chasbec

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Mar 24, 2013
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130
Location
Hudson Valley, NY
I just picked up a rusty OLD Merrill Bros 6" vice over the weekend. I wanted a new project and came across this. It is a BEAR, weighing in at about 125 lbs. Just about killed my back moving it off my truck and setting it up for the "before" pictures. The main screw turns but the slide shaft is seized with rust. As you can see in the pics, there's clamping apparatus with a screw and handle underneath so that it can be rotated on the surface to which it's mounted. There is some heavy pitting on some of the parts but the castings are all intact. The main handle is straight, but looks shop made.

I've had good results restoring a smaller (4") vice previously but it wasn't in such rough condition to start with. This one is going to be a real challenge, but I'm excited to get started. I think I will start with a diesel soak and see if that will allow me to disassemble it so I can really get to work on it.

I've seen some incredible restoration work done on this site and I'm all ears as far as recommendations and suggestions. If anyone has information or trivia about Merrill Bros. vises I'd love to hear from them. My first question: Does anyone know if there's a place I can get replacement jaws or will I have to get them custom machined?

Here are some "before" pics:

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drivesitfar

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Chasbec: i freed one of my vises that was even rustier in a bucket of vinegar which might be a bit cheaper and not quite as strong smelling as diesel which i heard also works. Jeremy's Electrolysis suggestion might be the cleanest and cheapest way especially if you are planning on doing a few of these.

now to the jaws which don't look original. Both jaws are have chunks missing on the underside of the cast under the jaws which might need to be replaced somehow. are you or do you know a good welder? both jaws don't look original so maybe take them off if you are able to somehow and then post some pictures. also it looks like one of the previous owners drilled in the back of the static jaw to put screws in from the back on that side's jaw.

it is an interesting and big vise so wishing you the best and i'll check in from time to time to see how you are doing.

check the vise thread for a lot of good information and one of GJ's best vise guys is KMScott so you can maybe PM him about your jaws which might cost quite a bit to fix correctly.

also if you want to post one before like you just did on the Vise Repair 101 thread i started telling about your vise and what your plans are and then quickly after posting reserve the next post for after pictures and descriptions of what you did so maybe it will help the next guy with a vise like yours or a similar issue. good luck
 
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Filson

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Jun 14, 2013
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Chasbec - A lot of great info was provided above. I look forward to seeing how this turns out! Don't forget to swing by the VISES of Garage Journal thread and post your before and after pictures once it's done!
 
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Chasbec

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Mar 24, 2013
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130
Location
Hudson Valley, NY
Thanks for the great feedback guys. I was worried about how I was going to dispose of the diesel after soaking it so I think I'll probably go with the electrolysis. Is the residue from that (using washing soda) non-toxic and safe to pour off in the woods after it's done? I'll start to address the jaws once I can open them and get a closer look. I was hoping the holes pointed out in the static jaw (also present on the dynamic jaw) were made like that in the factory. If not, they should be easy enough to fill in. Once again, if anyone has any information about these vises, or even better some pictures of one in good condition, that would be fantastic! Hope to get started with the electrolysis this weekend.
 
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Fretters

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Jan 25, 2014
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South Yorkshire, England
Nice bit of kit. Should look a treat when it's done.

Chasbec said:
Is the residue from that (using washing soda) non-toxic and safe to pour off in the woods after it's done?
Click to expand...

Absolutely. Most plants will love it, as it's iron rich. If there's notable grease or oil in there, just pop some washing up liquid in first to break that down, (though the sodium carbonate will have likely already seen to that), but otherwise you're peachy just dumping it.
 
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drivesitfar

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http://www.garagejournal.com/forum/showthread.php?t=237752&highlight=electrolysis

i provided a link to a great thread on Electrolysis if you have any other questions and unless you are putting nickel plated projects or maybe stainless in your tank Fretters is correct about disposal. it's discussed in this thread too.

i'm pretty sure he puts his leftovers from his E tank in his garden to give his food a bit more iron if you happen to see some of the big chunks of steel he moves around he probably needs some extra.:D

once you get it apart it will be a bit easier to move around.

good luck
 
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Filson

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Oh yeah, it's safe. I just pour it in some bottles and drink it like a sports drink. Electrolysis bath = electrolytes, right?
 
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Chasbec

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Mar 24, 2013
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Hudson Valley, NY
OK, I got my electrolysis bath going this weekend and it seems to be working really well. Drivesitfar - you are correct. It looks like the static jaw is missing a piece. I'm P.O.'d at myself for not noticing it when I got it, but I'll just have to work with it now. I'll be able to get a better look at both jaws once I can get the whole thing dismantled.

Anyway, about the electrolysis bath assembly... I started by buying a big storage bin and some galvanized baling wire at the local hardware store. I cut the bottom out of a milk crate and used that as a platform to set the vice upon. I cut one of the 6" x 24" steel grates in half and luckily, the halves just happened to fit perfect in the milk crate bottom. I used two full grates along the sides of the bin and a half grate on each end. I wired all of these in a daisy chain which lead to a nut and bolt outside of the tub. I then wire brushed a portion of the main screw on the vise, wrapped baling wire around it and terminated it on another nut and bolt outside the bin.

I had to go to several stores to locate washing soda but ended up finding it at Wal-Mart.

I filled the whole thing with water, hooked up my charger and watched it start working. My biggest worry right now is that the bin could burst. If it does, I'll build a cradle for the next one. The whole thing was fun to do and has been a great learning experience!

Anodes in the milk crate bottom:
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All anodes laid out and wired:
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Vise placed in tub (just fit without touching any anodes or anode wires
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Battery charger connected! (Waiting for explosion:scared:):
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3 hours later:
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drivesitfar

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Chasbec: your E bath set up looks great and i wish you the best. just a warning when using that much water in one of those style tubs I've seen them crack and break in the middle on the sides where that one side of yours is trying to blow out.

hopefully it will do great. i'm planning on using the black ones with the yellow tops that Costco sells for about $8 that are a little heavier gauge plastic in case you want to upgrade yours for those awesome grates you found to use.

hopefully it not only removes the rust, but also allows you to start taking it apart.

good luck
 
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Outlawmws

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The Badlands
Two things:

Get rig of the Galvanized wire. go to the section where they sell re-bar and get the plain iron wire. its cheap and won't contaminate the soup with zinc (heavy metal)


On Drives comment on the tank: Make up a board with a couple of blocks to hold the side in better and support them
 
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drivesitfar

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Chas: i think he uses wire they tie rebar with which would be in the section of rebar and cement in most hardware store. also i think they call it baling wire because i think in the old days the farmers tied their bales of hay with it.

Outlaw is right that you shouldn't put galvanized or probably stainless or copper in the mix to eliminate fumes and then you can just dump the waste in the garden or flour beds that could use the extra iron.

also another idea if you really want to keep using that Rubbermaid or plastic tub is to make a wood piece that goes across the top with a couple small wood pieces screwed into the board to hold the sides from bulging out.

good luck
 
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Chasbec

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Mar 24, 2013
Messages
130
Location
Hudson Valley, NY
Ugghhh... That's kind of a sore subject. After it finished cooking in the electrolysis bath (which did a great job getting rid of all the rust), I took it out and oiled it down. Then I found a break in the main body casting :(. I was getting ready to move right after that and ended up throwing it in a dumpster. That really sucked, although, I did enjoy learning all about the electrolysis process.
 
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