Galion 503- Destroyed Ring and Pinion

[bsinclair]

Big update on this Galion, member here max mac got us a set of gears, and I finally have time to get them in the machine. I am wondering about a few issues I have found though, big one being the ring gear carrier flange is distorted, like a bent bicycle wheel. With the ring gear carries in the machine, I have 0.078" runout on the outer most part of the flange, 0.035" on the inner diameter of the flange, and .15" on the ring gear "hub" diameter.



Any ideas on how this bent/warped/moved? You can see the mating pattern on the old ring gear and the carrier flange too.






I am wondering if it would be a bad idea to face the ring gear carrier flange square in a lathe, and have a thick shim made go between the ring gear and its now thinner mounting flange.

 

[bsinclair]

To clarify, I want to machine this flange with the blue line square to the bearings, and flat, might have to take off 0.050" I suspect. And then make a thick shim to space the ring gear back to its position. It is wavy like a spring washer right now.

 

[56wrench]

First put an accurate straight-edge across the crown gear and check it for flatness on the mounting surface to make sure it is not dished. I would only use a shim as a last resort if there is no other way to compensate for material removed. A better way would be to shim the bearings if possible

 

[OzDozer]

I would be avoiding taking any material off a flange that has already indicated it's prone to warping.
My preference would be to build up the low spots with some silver brazing alloy, and then machine the flange flat.

 

[Nige]

I would be avoiding taking any material off a flange that has already indicated it's prone to warping.
My preference would be to build up the low spots with some silver brazing alloy, and then machine the flange flat.

Would build up using metal spraying and machining back to size be an option.?

 

[OzDozer]

I've never had any success with plasma-sprayed metal on crankshaft rebuilds - they always failed when the sprayed metal peeled off.
Not sure if it was an engine-specific problem (Komatsu HD465-1 engines), or if the plasma-spray operator had deficient processes. But I have never used plasma-spray rebuilds for crankshafts for the last 30 years.

However, in a situation such as the ring gear flange, where there's no surface movement between the plasma-sprayed metal and the ring gear, I believe that process would probably be quite suitable.

 

[Welder Dave]

What about O/A torch sprayed buildup? It works really good for shaft buildup and I think would work on the flange. Set it up in a lathe or on a turn table to spin slowly, heat it up evenly and spray the powder.

 

[bsinclair]

Big update here, she is all back together an running!

I did end up making a "shim" to put the ring gear in the proper place after machining down the wobble in the ring gear carrier. Glad it is now out of the shop space! Thanks for everybody's input and help.