Replacing broken shaft in conveyor roller.

In this video I replace the shaft in a conveyor roller. The original shaft had snapped where it had been welded in, the weld had caused it to be brittle. A new bigger diameter 35mm shaft was used to help eliminate the weak point.
The first job was to cut out the old shaft with the oxy torch then remove the old end plates. I cut away as much as I could without damaging the outer roller but it was difficult to find the separation line without burning  the roller, the second end was removed with the arc air gouger giving a faster and better result.
Once the old welds had been ground down, 2 new end plates were cut out with the cnc plasma then machined to size using the lathe.
The new 35mm shaft was then cut to length in the chop saw then both ends were turned down to 25mm in the lathe. A new keyway was also cut into the shaft using the milling machine.
Once all the machining had been done, the roller, end plates and shaft were assembled and tacked into place. The rolled was checked with the dial gauge to make sure it was within tolerance. The ends and shaft were then preheated before welding. And that’s the good complete.

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