Repair of broken brake bands

[puffer@rpi.edu]

I found that both of the brake bands on my CAT22 were in need of repair and re-lining. One of the threaded rods, spring and nuts were broken off and missing. I managed to break the other threaded rod when I tried to remove the rusted-on nut. In order to repair the brake bands I purchased 3/8"-24 threaded rod, and coupling nuts from McMaster Carr, and B18-153 springs from Century Spring. I cut off, then drilled out the broken threaded rods, then welded in the new threaded rods. I cut the coupling nut in half and ground them down to the proper profile. I made an extra set in case I need it in the future. Then a trip to the local truck brake shop for new linings. An easy, quick, low cost fix to a nagging problem. See Photos below. I have included the old spring and nut, as well as my reproduction parts. Hope this helps others faced with the same problem. Ray

DSC_0122.jpgDSC_0123.jpgDSC_0124.jpg

[Mike Meyer]

Thanks for sharing that repair job, you are obviously pretty handy around a lathe. How much did the new linings cost just out of curiosity?
regards
Mike

[puffer@rpi.edu]

Thanks for sharing that repair job, you are obviously pretty handy around a lathe. How much did the new linings cost just out of curiosity?
regards
Mike

Mike,
I did not need to use a lathe. I just build an alignment fixture to hold the brake band and drilled out the old threaded rod with my drill press. I drilled all the way through the boss that holds the threaded rod. Then I used a bench grinder to grind off the threads of the new rod where it passes through the boss, then I MIG welded the rod to the boss on both ends of the boss for maximum strength. I also used a bench grinder to shape the retaining nuts to the right profile to fit.

I am sure I paid too much for the re-lining, I think it was around $70 each from a local truck brake repair shop. At least I did not have to pay for shipping. Ray

[Mike Meyer]

Mike,
I did not need to use a lathe. I just build an alignment fixture to hold the brake band and drilled out the old threaded rod with my drill press. I drilled all the way through the boss that holds the threaded rod. Then I used a bench grinder to grind off the threads of the new rod where it passes through the boss, then I MIG welded the rod to the boss on both ends of the boss for maximum strength. I also used a bench grinder to shape the retaining nuts to the right profile to fit.

I am sure I paid too much for the re-lining, I think it was around $70 each from a local truck brake repair shop. At least I did not have to pay for shipping. Ray

$70 each sounds reasonable to me, particularly if they supplied the lining material and rivets, it takes awhile to do the job right. Nice work with the hand tools, I do a lot of that too, one of these days I need to buy a lathe, and then learn how to use it!
regards
Mike

[puffer@rpi.edu]

$70 each sounds reasonable to me, particularly if they supplied the lining material and rivets, it takes awhile to do the job right. Nice work with the hand tools, I do a lot of that too, one of these days I need to buy a lathe, and then learn how to use it!
regards
Mike

Mike,
In my third career, following a career in the military and a career as a researcher in a leading university, I am a professional woodturner. I have a great wood lathe, but really also want a nice metal lathe. If only I had the space for it. See my web site at: www.RP-Woodturner.com. It's still a work in progress, but you will get the idea. I guess I need to build an annex to the addition I built onto my garage. Too many hobbies and not enough space or time. :-) Ray

[Mike Meyer]

You are very clever with the wood lathe, congratulations.
regards
Mike

[STEPHEN]

Nice work, thanks for sharing!