JackD6-5R wrote:

I have thought about having a strap of steel rolled into a circle the right size to fit the idler then welding it to the idler where the chain runs ,but haven't yet tried it.
 
if you made it a slight shrink fit and used a high temp retaining compound that might work. or you could still make it a shrink fit and spot weld it on. and use a medium grade steel instead of mild steel. it would be quicker  than fully welding neater finish. i wonder if you could get some pipe of the right dia to do the same thing out of 6 ft of pipe you would be able to do a full set of track rollers. the front idler would still be a pain.
 

Thanks for everyone's input.  I am probably going to grind them because I have OCD and I would hate to look at uneven welds all the time.  I will post some pics of the jig that i come up with.  

I am gonna ask a somewhat silly question, its still idler related, but Persian Orange: Many Allis Chalmers crawlers I have noticed that the front idler is always built back up (guessing) in a perfect zigzag pattern. Is that AC factory specific? Just a bead, not completely filled in. Thoughts? JM

I did my 5J- D2 back in '84, and worked it since, I would say not to hard. Welded up the rollers with 7018 and turned them on a lath just to get my welds round. Worked out well, and still running them. Easy way to do it.

second that Vansgarage

i've done a bit of patching on blade and undercarriage pieces with 6010 and 7018 and it seems to be holding up fine...i even bought some hardfacing rod to compare difference in wear and so far i can't really tell much difference?? i need more time and hours operating to get a more accurate picture but so far so good..
-i'm operating in dirt and clay...with different materials i'm sure results and mileage will vary

I had a snow plow blade on a truck for years. The corners wore down from riding the curbs in the lot I plowed for 20 years. I finally broke down and put a new mold board edge on the blade and decided to be smart, hard faced the corners where it wears down so easily. First time out I snapped both corners off where I hard faced them. LOL.