Body repair Pontoon EX PC200

Side Body

hydraulic Hose covers

Repairing processes :

Cut the eye pad and cut the broken cover U beam

straighten the uneven side body with heat and hammer and replace the side cover with new U beam

Fabricated eye pad

Beveled and weld all around   

fabricated hydraulic hose covers

All repair process has done using :

Manual cutting oxyacetylene
Grinder
SMAW/stick welding low hydrogen 3.2 mm electrode by kobe 7016
and other tools like ruler , stone pencil , hammer.


 

 

Rebuild stand for Generator/Genset using scrap

-re-position nut holes,
-added feet

Note : I Have to add a fuel tank stand too the problem is there is no space for that so i have to find more scrap and luckily i found it.is not perfectly have the same length as the main stand but it can work

Made a Fuel tank stand and battery bracket and weld them together onto main stand. for connecting the fuel tank stand with the main stand i used  cover plate 8mm thickness about 150mmx100mm length to joint it with the main stand and weld vertical up at the front side , and for the back side i made gap about 10mm make a lap joint  and weld all the way up same apply at the other side.

after some painting job...

SIMs cap lift cylinder (fabricated)

tools : manual oxyacetylene cutting
           ruler
           stone pencil

Material : plate with 3mm and 5mm thickness

Replace Bracket Trunnion Blade Assembly

Bracket Trunnion :

weld with SMAW / Stick welding

Setting :

Put a mark on the blade done when the old Bracket still attach , using a stone pencil (or something sharp make sure the mark not missing because you step on it when you weld )  and a carpenter ruler  (look something like this)

and cut the old bracket using manual cutting oxy acetylene   . grind it .. put the new one and weld it.

Fabricated Cover lamp and Bracket (upper cabin component Bulldozer)

Done With :

Stick welding , Grinder , Oxygen acetylene manual Cutting.

Materials : 3mm plate , 8mm plate 

Bulldozer unit #1870 repair Grill radiator

Mechanic on the job

Add caption

Bar plate attached on the back side of the grill 

Grill Radiator DZ # 1870

Task : Repair Grill radiator DZ # 1870

first thing i have to do some analyse first  on this Grill radiator

it is made from two plate welded together 8 mm each together make 16 mm thicknesses

and there is a bar plate (5 mm) width x long  750x750 mm  holding the back part of the grill it is welded to the back side of the grill.

i released the bar plate from the grill first using manual oxy acetylene by doing that will make easy  to bend the grill  in to it place.

this is how I've done it what i am used as a tool is :

-manual oxy acetylene with heating tip 

-and a tool called Baji (the one with the orange arrow) 

-hammer 

step by step i heated up point it not directly on the bend spot but the spot before it and using Baji i had hammered it and moving forward until it straight.

i have still got a small bend at the corner I've managed to heat it up and punch it using  hammer .

and it worked.

unfortunately the dz #1870 unit has been hold , so my leader have ordered me to install it back.

so i am not 100% done with it, i don't got a chance  to make a new bar holder at the back yet.

   this is how it look like..