Rebirth of a 6 Foot Flail Mower

[pycoed]

What is it with the right side roller bearings? Replaced mine 4 years back (both sides: left was reasonable, right was shot) & the other day I got a squeaking noise & upon first look it seems the right one needs doing again! I agree about the useless grass guards - I try to cut all the rushes away from mine after every use, but it  never  seems to work.

[awemawson]

I suspect in this case the roller has taken a knock cracking the weld between it's tube and the cotton reel afair that slides into it and forms the stub axle.

Maybe I didn't Vee out the weld enough originally but is HAS lasted ten years. Left hand end is still intact but will get a close inspection when I can get someone to help me lift it onto the welding bench and maybe I'll gouge it out with a die grinder a bit and weld it 'just in case'. The right hand side I will be able to form the  Veeing on the lathe before re-inserting it.

Good news is that the new bearing is now in the post.

[awemawson]

So a bit of fiddling around while waiting for the bearing:

First I turned off any remaining bits of weld that would prevent it being slid into the roller tube and did a test fit - yes it fits.

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Then I tidied up the bit of the stub axle that will fit into the bearing insert - I'd been whacking it with a sledge hammer to try and get it out so it was rather bell ended - a combination of hand filing and filing in the lathe. Now all marginally below 1.25" by a few thousandths so the bearing insert should fit.

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Then I increased the beveling on the circumference of the end plate to allow for a bigger weld:

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Back to finger twiddling - I'll clean up the end of the roller tube by angle grinder when it's up on the welding table when I can press gang someone to help.
 

[AdeV]

Came out acceptably for what it's for.;

Weld up all the holes, grind flat, polish to 1000 grit. Perfect!

[awemawson]

Very good Ade - wait till you see the next bit of welding - definitely farmer style !

So the new bearing arrived:

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I cleaned up the inside end  of the roller tube, placed the spool in and packed it to central with temporary  bits of welding wire then tacked it and removed the packing. Welded it up which went horribly - needs more fettling and a bit of pad welding in places. A job for the weekend - guests tomorrow and I'm now knackered.

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Certainly needs a bit more attention - probably strong enough but the roughness will gather grass.