Martyn Williams Any Tips On Welding This

Hello K of O
When I was a apprentice,we were given projects similar to this.One method was to drill peg the broken teeth then build up with cast rods,the peg method would give it strength, but you had to preheat the job to prevent fractures.Then when you have got the right profile,grind and file to finnish off.But these days there are a few companies ( but are getting less) within the UK that can make up new gears.A very good friend of mine, the late great Fred Dibnah had gears made up to a pattern for his Aveling Porter steam tractor.
I think it may be more cost effective to get a replacement made than a repair job.As its repair is only as good as the skills of the person that does it.
I have repaired,using cast rods small gears with success, but I think I would not be good enough to take on a bigger job.
Hope this helps
Martyn
If its just slight wear or a chip,I would give it a try with a cast rod.heat the gear,but not red hot.Try to find the composition of the gear.The gamble is if not done right,the repaired bit will break off causing more damage than you had in the first place.

As long as we are on the topic of welding, i have a d2 5u pony that has freeze cracks on the bottom of the block (under the piston).

I have an arc welder and a mig welder. Not an expert but i am capable. Is this something i could attempt if so how (i e what rod, what settings, do i need to preheat or pin the cracks etc?)

There are some good welders here and i should probably have them do it but i am willing to risk the block if i can learn.

Bob

Hello Bob
Its a common problem on the pony engines.I patched mine about 5 years ago and its fine.To prevent this problem,use antifreeze or drain down system .To make sure,remove cylinder heads and flush out sedement.This will also help with cooling.
Martyn

Try it yourself,make sure that area to be welded is clean,warm up area with a blowlamp.Don't try to weld it in one go.Do a bit,stop then do a bit more.Don't rush the job.I used cast rods.

Whilst I would not class myself as an expert welder, I have had some success on gear teeth using dissimilar metal electrodes with an Arc welder and pre-heat.
The rods I prefer are Inox DW (Oerlikon) and EutecTrode Xuper 680S (Eutectic).
As Martyn says, do a little at a time and allow to cool inbetween welds.
It goes without saying that you must have a clean and oil/grease free surface to deposit the weld onto.
I would imagine that with the right type of wire, MIG welding could be used as well, but I've no experience of this myself.