Reply to AJ.:
Go to the link below where there is a short wartime film made by Cat about reclaiming parts,its only a four minutes long showing the reclaiming of a piston,removing a ridge from a liner,grinding a crank,building a shaft spline, putting a rim on a sprocket,building a rail,repairing a head,rebuilding a roller and reshaping a cutting edge.
AJ
http://media.putfile.com/Reclaiming-parts
I have a Berco book and it seems as though most Berco rails are somewhat taller than original Cat rails. The problem may be that although your rails are still tall enough they may be worn through the hardfacing. It might not take too much to lay a layer of hardface on them, seems like I heard Stoody...50? can't remember for sure, I know I have some someplace. You say your pins and bushings are 100% gone, then you are looking at new ones because they have been turned. It will do no good to build your sprockets back to standard because your chains are out of pitch.
This is what I have been thinking lately.....what do you other guys think of this... The sprocket wears at the tips of the tooth, not so much in the root. If you use those weld in cups wont they increase the diameter of the sprocket enough to compensate for the increased pitch. Think about it and tell us what you think. It might look kind of messey but they might give you some more runnable hours.
I have given this some thought lately because my D8 tracks are shot. My biggest problem is the rail height is about 4" on one side and 4-1/8" on the other. This is over 200% worn and long since through the hardface. The only answer would be to weld on strips and hardface. On a lot of old Cats someone has put new pins and bushings in worn out rails in the past. I did it myself once, its called undercarriage denial. My left track is still in pitch at about 98% wear. My right track is climbing the sprocket at 110% wear.
The guy I got it from said I could run it the rest of my life but I know better and paid him accordingly. The pins and bushings could be turned into some other rails but who has the $ for that. I am trying to visualize another set of tracks with about 25% left...I can smell them I know they are out there someplace.
I don't mind tearing up that sprocket, it needs re-ringing anyway. I don't mind the rollers wearing into the pin bosses, they are soft. It has some more hours before the rollers hit the pins but the pins will tear up the rollers and the rollers are real good. The biggest problem right now is the ends of the pins are tearing up the rock guards and I hate to see that go any farther.
Just some stuff to ponder.
Tom