Forensic metal failure analysis. This is a basic study as to how things break. This exact failure can be seen in u-joints, leaf springs drive lines. I got my introduction into failure analysis when I worked for Cummins in the late1970's, they used to publish training manuals. So we would get a new booklet on various truck related issues, work would quit early, pizza would be served. They did things like drive line vibration, different topics. The one i remember was metal failure types and how to read them. This one as you say probably started in the unnecessary hole. I think the term that was used was "shelling" [as in sea shells] the pattern from where the crack originates leads directly to where the crack starts. The most interesting one I had was a harmonic vibration. The are ultra sonic vibrations that melt metal molecule. Those training sessions that companies used to do in the early days was great stuff!

2:32 totally sounded like up to me also! Great work guys.

I really appreciate you showing the part of the plate not going as planned, IDK if I can speak for anyone else but seeing someone else go through the same struggles helps me at least take a little pleasure off myself knowing Im not the only one lol. I dont have the experience of you, and I dont work on equipment like this but once you figure out the best way I am typically about done with the job and dont see anything like that for a long time always something new I love it thank you.

NICE JOB !!! The "Cardboard CAD" ..........was priceless ......... never heard that one before.

That CAD-joke was nice. Have to remember that. 👍🏻

I love it when the pros make mistakes and admit it. It is refreshing to me, I constantly make huge errors, so these videos don’t hurt my self esteem too much

Kudos to the apprentice for keeping it cool in the eye of the storm

I've done a little welding in my time and have been a loader operator for 27 years. You repaired it as well as could be done for structural integrity. I'd trust it. Good job.

It des not take a welding engineer to see why that member broke...That huge hole in the middle reduced 1/2 the strength of it IMHO. Super great repair job Greg.

This guy is a maistro when it comes to welding. I see a huge repair, and he makes it look as simple as me making a peanut butter and jam sandwich. I don't know how much that repair costs, but it's worth every penney.

It's going to fail it wasn't welded with an old high school surplus Lincoln Tombstone with rods that the dog pissed on at least six times while drinking a case of Busch Light while the girlfriend Tammy screams on about how that case of Busch was supposed to last until Monday between the both of you.

About that 1/2 inch plate. As you know the customer is always right even if he’s wrong Thank you Sir for this video & chance to learn

I did a similar repair on a 966 back in the mid 70’s. I put a shaft in the lower pivots and in the broken one to square off of.

Top work young man, including admitting to a mistake. Honesty is the best policy. Well done.

Oh, man... That pivot arm juuuust made it, with the plate underneath it. Great video.

Great job, Greg!! I sure like your approach, as always!! No one could have done a better job than you!! Thanks again, Vic!!

Gotta love that CAD system! (Cardboard Aided Design)

*On Fire Welding* Bravo well done, thank-you sir for taking the time to bring us along. GOD Bless

Saturday with On Fire Welding! Alright! Coffee on! Cheers!;-)!

An engine hoist/cherry picker is really handy for hanging things like that. A little bit more finesse on adjustment so to speak, and it doesn't tie up the forklift. Your video reminded me i gotta get some more wire wheels and a new face shield 😂 And for the record i heard stop.

Your CAD joke was great timing. I commented about your excellent CAD skills this morning on your excavator wing video

The hole location for the angle sensor is wetoddid. The mistake was easy to make but the designers letting such silliness leave the factory was goofy vs. welding a shield to protect the electrics rather than burying it which no doubt someone was proud of because it looked cooler. BTW the squirt bottle trick is classic and works a treat with water-based machining coolants too.

That's a good repair. It's no wonder why it broke there between the hole in the cast steel. And the drill holes in the weekest points. I understand that it's there to protect the sensor from damage. But also greatly weekends the structure of the casting. Great repair job in the end.

Happy to see moisture in your yard. Very dry at my home NW Alta.

Chainblock on the fork will save friendships 🤣🤣🤣

Like how you show, not everything goes as planned, and can admit errors happen, great vid

Great stuff as always! Thanks for sharing

Hi Greg we all think we are helping out by engineering some Strath into something and find we have done to good a job to keep the costumer happy then have to go over the brilliant job we have done, I don't feel so bad now to see this can happen to a professional in his line of work I was more than surprised to see how you got that starched work back into place another fantastic job by the man who never seems fazed by the work he is given to do thank you for showing us how to get around a problem and thank's for another great and interesting video. p/s i just hope the customer is happy with the work you have done for them.

Bet that was exciting at the moment that broke! I appreciated the fact that you preheated it. It amazes me at how many customers have told me over the years that I was the first weldor they’ve ever seen do any preheating. Naturally, they assume, since they have never seen it or understand why, that I don’t know what I’m doing and it’s just a waste of time 🤦🏻‍♂️!

Nice work, thank you for sharing with us. When I heard that extractor pop it hurt my feelings way over here to. Funny thing is broken taps and extractors sound about the same when they give up. As we say in the shop if your not breaking anything your not doing anything.

Love your work ,Always something different .Cheers from Australia.

Too funny with the directions 😂 I have these moments with my apprentice all the time. Drives a guy crazy some days haha

Excellent job man. Impressive fix.

Some repair that young man! Have got a similar T shirt for mistakes when welding, but I had to cut off and start again. Great work and video.

Beautiful work. The 3m Cubitron disks are amazing. I’m glad that you forgot about mounting the position sensor. Makes me feel better about my mistakes.

Hey Greg, great to be back, hope you have a wonderful weekend, Paul in Orlando, Florida......

Wow! Cool! Repair! Thanks for sharing! Awesome job! 👌👍

Beautiful work, and yes, the customer is always right. They want a plate, they get a plate.

Thanks for the welcome back always give OFW a👍 up

I imagine it took years to gain the skills to do this work, but Damn, you have a cool job.

Very nicely done, that was a lot of effort! Cheers

Really great workmanship!

Great job young man. Obviously it's a stress point and more is better. Up and stop should brought out the comments.

its like watching cartoons on Saturday mornings! love it, enjoying your video while enjoying a coffee.

That was a big welding job there lots of fun lining it up to weld but i must say thats nice work...

Now that i had time to finish watching the video, i had to comeback to say, my go-to on broke off bolts is to weld a washer to them, then a nut on top of washer. Then let it cool before turning the bolt out. May take a couple tries but It works almost every time. I spent way to much money on drillbits, extractors, and taps in the past.

There is a serious amount of work, preperation and messuring before even start welding... I would very much like that job....

it is so nice to watch a professional work. Good job

It was only broken the middle part....Amazing repair...Thx OFW...

you get the messes do it wright you are a true craftsman

nice work. Like all pros, you make it look easy.

You do nice work, I am learning a lot from you!

❤the Cad system Ha Ha 😝 we had a flame cutter table with an eye and we did just what you did and trace it on Mylar paper and burn it out. Takes me back to the 90’s

Nice repair and that 3M disk is a grand tool... Those tapped holes for the sensor certainly appear to have contributed to the failure. Maybe the design would be strengthened if they used surface welded studs for the sensor plate mounting, rather than drilling so many holes into what must be a highly stressed part of the loader arm?

Always a pleasure to see your work. 👏👏

I can relate to the cad/cardboard design good job

Way to go Gregg!!!!! It's good to be good and even better to be lucky!!!!! I know the customer isn't always right but he's still the customer and we give them as much of what they want as practical. Good to see you back.

This nice clean break look like oilsand fort mcmurray - 45 below zero.yes,repair this is hell job.thanks video again.😊

Sounded like you said up to me too.

I am reminded of the Star Trek pilot episode The Menagerie the aliens tell Pike, when they were putting the girl back together they had never seen a human so they did not know how to do it. So she was all deformed. But I digress, a wonderful repair job not with standing the error, your right you never saw it together, so you cannot be expected to know. Life is here to try us, it can be fixed, I still think you did a lovely job in putting this back together. Well done matey well done.

41:30...love the way you think to get the job out on time......Bravo easy fix, easy repair later....cut tacks and then attack the broken bolts....

interesting, never ceases to amaze what breaks on earthmovers...

those are always fun to repair. gotta wonder what it was like when it finally snapped off. never get to see the action just the aftermath.

to be fair i thought you were saying up as well as for the plate repair looks good! id put 4 studs to mount the sensor plate an called it good

Great Video thanks for sharing your skills.

Up and stop does sound similar. Some blasting crews will omit "five" when counting down b/c it's too close to "fire". In my language, some people won't use "what" or "yes" on devices like CB radios because they sound similar. "What" becomes "repeat", "yes" becomes "confirmed" or "agreed". Hoisting (heavy) stuff, crane work, is a career all in itself. There's probably something to be learned from there. If it was me, swapping "stop" with "halt" should probably do the trick for this situation. There's a part in the book Dune about Battle Language. In the book, Battle Language is designed so that important words likely to occur together will be easy to tell apart. Which does make a bit of sense.

Thanks for the video.

Hey OFW quick tip here: Get the Mayhew 37345 extractor set, better than those spiral ones... Works 💯 of the time... 👍🔥👍

You da man, cold in PNW as well, cheers

Greg, time for a beer on a well done job......PB

you did in fact say up, not stop lmao

Great video! Thanks!

U don't great job editing and narrating your videos. Speeding up the video is great for not losing any of the content during the process.

When something breaks and you really didn't abuse it, I think it's a good idea to reinforce it. It really shouldn't lift anything heavier than it is rated for. Doesn't look like a good way to do that sensor. I thought it looked like a factory lifting point was the reason for the hole.

A good friend is a welder since almost 30 years.. he would complain about everything... " wrong weld here... angle not enough... no holes to weld on the support part.. yadda yadda yada.... " Completely going nuts 😂😂😂 I would not be able to weld even close to your stuff. Way to go.. GREETINGS from Switzerland...

WOW what job this was you knocked out amazing skills 👍👍👍

I like your CAD design

Cad 😂😂😂 Cardboard assisted design 😂😂😂 Excellent job Greg Filling in those large gaps,sure sets an experienced welder apart

I don’t even own a welder yet find your videos very interesting. I would’ve used lots of JB Weld 🤣

Great repair.

Anyone can come up with a reason for that opening, that "eye" on that forging, I'd be really interested to hear it. Anyway, that's where I'd add a shaped plate, bevel sides and 100% weld to have any hopes, friends. Elasticity on that arm only causes metal fatigue.

Nice, how did you check the hole was square both ways to the other machined holes as it must have pulled when you burnt in the wire as they always do.

it´s magic again! great job¡

That took a lot of abuse before it broke ! That my opinion anyway ! Great job as always very professional looking seeing how it was brought completely off !

Great job as always very interesting 🦘

Nice project, thanks for sharing

Nice job!!

I dis this same repair for west coast sand and gravel in visalia, the new mount for the position sensor came with a new bolt pattern, it was a 950k i believe, got very lucky and didnt have to line bore afterwards, it all pinned up

One welding repair professionally done ❤

Nothing that some fire 🔥 can’t fix !

Need that OFW merch! Love to rock one of your hoodies around the jobsite! Ironworker here out of local 207 Youngstown! Keep up the great vids!

Awesome job

great work bro i was wondering what that big hole was for🤣

Kinda like watching Bob Ross paint trees and the landscape, perfection!

Brilliant channel 👍🏻👍🏻👍🏻👍🏻🇬🇧

Say whoa instead of stop or learn hand signals. It’s what we did in the paper mill where it’s so loud and worked well.

Good looking repair.

its not a simple job if you are a perfectionist 😀

I'm a carpenter and I just love your videos. Thank you so much for explaining the details and showing the different steps. It's soooo interesting!!!!

Good job, good welding 👍