how about some after pics of the carnage? im dying to see how bad he killed them

 

I as well would like to see the carnage.

-Enjoy
fh : )_~

 

For your viewing pleasure:



You get the idea.

 

Well, at least it stuck...

Bummer.

 

wow, that guy is terrible. he would have been better off not using any fill material. i bet he could have taken care of that without the fill rod, just used the aluminum that was there.

 

Might be able to tap it and use barbs?

Pro welding there sry man i was looking forward to this as I liked the looks of them

 

New caps are in the works. We'll see what material they are and how they turn out. They're either going to be aluminum again or brass. This time I'll receive them welded, brazed or soldered.

 

Let me know how well they work then, I'd love to try them if they hold up betetr than the olives

 

I see several issues that caused his problem ...

Coolant/Cutting fluid or some other contaminant in the porosity of the aluminum.
Blunt tungsten.
To much current/heat.

-Enjoy
fh : )_~

 

x2 about the tungsten, etiher it was blunt or pointed like you'd use for steel unstead of rounded. also he tried to feed too much rod into it.

 

Something else I just though of, he may be grinding his tungsten horizontal versus vertical...

What I mean by that is when you grind your tungsten you grind it so the grinding marks go lengthwise (or along the length) of the tungsten, not cross ways to the length.

That causes a large uncontrollable arc.

-Enjoy
fh : )_~

 

What about a slight interference fit between the caps and nipples and using Loctite sleeve retainer?

Jason

 

Been there already, he feels that would be inadequate do to the vibration.

I disagree, a good interference fit can be very strong, however there is a depth/diameter ratio that ultimately determines the strength, if the bore isn't deep enough for the diameter they can be weak. I don't know the formula, but I do know that it should be at least as deep as the diameter for maximum strength.

IMO I don't think it needs to be maximum strength, there is not that much vibration.

Lots of components like that are made with interference fits.

-Enjoy
fh : )_~

 

Pressing a hollow cylinder into the side of a cylinder w/o a flat surface to start your press can lead to issues. Machining a flat would be unsightly and I'd lose depth. If there was a small burr in the bore during the press, it would cause a leak.

I have reference material upstairs from my mechanical elements in machine design class which walks one through the design of interference fits. I also have the machinery's handbook which simplifies interference fits.

 

And so do I ... I also have done it a thousand times if once!

But it's your choice, it's your project, I could care less what you know or don't, I know what I know and I know what I don't.

[edit]

Sorry, I should not have said that, it's not true, I do care!
(Underlined cause STRIKE tags don't seem to work)

[/edit]

-Enjoy
fh : )_~