(YT)Cutting Edge Engineering

This Excavator Track Idler Wore Out WAY Too Fast… | Hitachi ZX225 Repair

(YT)Cutting Edge Engineering — Sat, 11 Apr 2026 06:00:15 GMT

This excavator track idler didn’t just fail… it wore out way faster than it should have.
This Hitachi ZX225 excavator comes into the workshop with a failed front idler, but once the undercarriage starts coming apart it’s clear there’s more going on than normal wear and tear. Used in rental and dry hire work, this 23 tonne machine shows exactly what can happen when equipment gets pushed hard. After inspecting both sides, one idler has already been replaced with the wrong part, and the other has deteriorated massively in just one month. To carry out the repair, track tension is released through the recoil assembly so the track plates can be moved and the master pin accessed. Once the pin is driven out, the track chain is separated and the idler and recoil assembly are lifted clear using the overhead crane. New idlers are installed, everything is reassembled, and the tracks are tensioned back up through the grease system to bring the undercarriage back into proper working order. What stands out most is just how quickly the damage progressed… and how much worse it looks once everything is removed. To find out what really happened, the failed idler is cut open at the end to reveal the internal damage. This is a solid example of why proper parts and regular inspections matter on machines like this.

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About Us:
We're a down-to-earth real life machining and fabrication workshop in Australia. We specialise in helping business in mining and earthmoving to keep their machines running smoothly. We love working on broken parts and the bigger the better! We upload new videos every week showcasing machining, welding, line boring, honing and all the other awesome stuff that goes down in our workshop. Learn how we tackle different projects and see the satisfaction of creating something useful. Subscribe to stay updated on our latest jobs and projects! Follow us on Patreon for even more content and behind-the-scenes glimpses or find us on Tiktok, Facebook and Instagram for a chance to connect with us.

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Precision Line boring a GIANT Mining Truck A-Frame! | Sir Meccanica WS2

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:42:56 GMT

Watch as we tackle this challenge! We’re boring out the eye of a huge A-frame from a Caterpillar 789 dump truck. This massive component is critical for the truck’s operation, it connects the rear wheels to the chassis and we’re aiming for extreme precision! We're using our trusty Sir Meccanica WS2 portable line borer to bore out the eye to precise tolerances, but the extremely hard material is putting our tooling to the test. Watch as we battle through insert failures to get this job done!

In this video we are using:

Sir Meccanice WS2 Portable Line borer

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Kurtis BROKE The Big Lathe AGAIN! 😅 | Apron Gear Repair ⚙️🛠

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:42:33 GMT

Disaster has struck the CEE workshop! Ever had a machine break down right in the middle of a job? Well, we did! In today's video, we tackle a major mishap on our big lathe – the reverse feed on the lathe carriage is not working! We start by inspecting the lathe's apron and remove the top cover to get a closer look. At first, nothing seems obvious, but upon further investigation by removing the apron cover plate, we discover the culprit: a gear selector fork that's broken in half!
Next up, the fun part: making a new replacement. We use our trusty milling machine and start transforming the metal. It's a bit of a puzzle, but with some careful measuring and a bit of ingenuity, we manage to make a brand-new gear selector. Reassembling the apron is a delicate operation, but we're confident we've got it all back together correctly. The moment of truth: will our big lathe work correctly and be back in action? Tune in to find out!

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Working on the Motor, Pulleys and Guard for Our HEAVY DUTY Tool Post Grinder! | Part 3

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:42:03 GMT

Get ready for another exciting instalment of our DIY tool post grinder build! In this episode, we dive into the motor mounting process, using our milling machine to drill and tap the base for a secure fit. We also machine up a custom spacer to ensure a snug mount on the lathe's top slide. Then watch as we craft the pulley system, complete with precision reaming and broaching of keyways, setting the stage for efficient power transmission. To ensure safety, we also fabricate a protective guard from sheet metal and securely bolt it in place. With the motor mounted and the pulley system complete, our tool post grinder is taking shape. In the next episode we'll tackle the VFD connection and conduct our first test run. Stay tuned to see this project come to life!

In this video we are using:

Hafco TM-26120G Centre Lathe
Hafco TM-1740G Centre Lathe
Hafco BM-63VE Milling machine

MISSED PART 1 or 2 of Making the tool post grinder? Watch here: https://www.youtube.com/playlist?list=PLUzFN5xVei7We1fjeizxX4NBPWE08WvBm

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Can we SAVE This Cylinder with SEIZED Gland!? | Huge CAT 24M Motor Grader

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:41:37 GMT

We're on a mission to rescue this cylinder and save the customer a hefty chunk of coin. This hydraulic cylinder off Caterpillar’s biggest motor grader has a seized gland and the customer has tried everything to break its stubborn grip, but nothing’s budging. Join us on a rescue mission as we turn detective, machinist, and welder all in a day! First, we start with machining a custom locking pin to get the cylinder setup in the lathe. Then we machine out the weld and remove the cylinder end before setting the cylinder up in the hydraulic press and removing the rod and damaged gland seals. Then, it's time for the main event: removing that stubborn gland without damaging the rest of the cylinder. This might sound straightforward, but there's a fine line between saving the day and creating a whole new problem. Unfortunately, the gland is seized solid and that means we have to carefully machine it out in the lathe, all the while keeping the cylinder barrel and threads in good shape. Once the gland is removed it’s time for welding the barrel end back in place, stronger than before. In just a half a day’s work, we’ll save the customer a lot of cash compared to a whole new cylinder – a win-win for everyone!

In this video we are using:

Hafco TM-1740G Lathe
Hafco TM-26120G Centre lathe
WIA 500i Weldmatic welder
Metalmaster HPM-150T Hydraulic press

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Forklift Cylinder Repair The REBUILD Comes to Life! 🔧 | Part 2

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:41:00 GMT

It’s time to complete this cylinder rebuild! 💪 In Part 2, we take the 10-tonne forklift steering cylinder to the next level. Watch to see the entire process including machining a brand-new barrel on the lathe, welding on the mounts, cutting internal threads, and drilling oil port holes on the mill. We then hone the barrel’s ID for a flawless finish before installing the new seals, reassembling the cylinder, and completing the job with a fresh coat of paint. Watch as we bring this cylinder back to life and make it ready for heavy-duty action once again!

In this video we are using:

Hafco TM-26120G Lathe
-WIA Weldmatic 500i welder
Sunnen HTA-4100 Horizontal Hone
MetalMaster HPM-150T Hydraulic Press

MISSED PART 1?? Watch it here: https://youtu.be/c4WBuE2mp38

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Transforming METAL into MACHINED Parts! | Manual Machining, Turning & Threading

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:40:25 GMT

This week in the shop, we're tackling a variety of machining projects. We've got some heavy-duty rollers to make from solid steel billets, which is always a satisfying process. Then we're turning our attention to a super tiny cylinder re-rod – it's like working on a piece of jewellery! Even though it’s cute we still have plenty of turning, threading and welding to do. And then to finish things off, we’re crafting a custom pin for a Caterpillar 3500 series engine cylinder head. It’s a precision job that will make a big difference for our customer. Join us for a mix of manual machining projects as we transform raw metal into finished parts!

In this video we are using:

Hafco TM-1740G Centre Lathe
WIA 500i Weldmatic welder

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Complete REPAIR of Massive Bulldozer Yokes! | Sandblasting, Machining, Metal Arc Spray!

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:39:55 GMT

Watch as we restore a pair of worn-out blade lift yokes from a massive Caterpillar D11 bulldozer. In this video, we'll guide you through the entire repair process, from the initial sandblasting to the final coat of paint!

First, we'll remove the rust and old paint using our Rapidblast dustless blasting system. Then, to ensure the structural integrity of the yokes we'll conduct a crack test using our Magnaflux Y8 magnetic particle testing kit. To provide a clear visual demonstration, we'll also use this testing kit to identify cracks in a mining truck strut rod. Once we've confirmed the yokes' suitability for repair, we'll measure their bearing surfaces to assess the extent of wear. Then, we'll prep the first yoke by machining an undercut and rough threading it in our lathe. After that, we'll transfer the yoke to our Shenyang lathe for metal arc spraying using our Metallisation i450 machine. While the first yoke cools, we’ll repeat the process with the second. Finally, we’ll finish machining both of them to precise OEM tolerances before giving them a fresh coat of glossy black paint to restore their original appearance. The end result is a pair of yokes that look and perform like new. Join us as we showcase the skill, precision, and attention to detail that goes into restoring these vital components!

In this video we are using:

RapidBlast SD140 system
Metallisation i450 arc spray machine
Hafco TM-26120G Centre Lathe
Shenyang CW6280B Lathe

https://quantumblast.com.au/rapidblast-dustless-blasters/
https://www.metallisation.com/
https://www.metalspraysupplies.com

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Front End FABRICATION & NEW Cab Build Begins! | Franna Crane Project | Part 22

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:38:59 GMT

We’ve got two pallets of cut and pressed metal sheets ready to transform the front end of our crane. Watch as we tackle the installation of new front guards, assemble and tack together a massive new tool box, and drill the mounting holes for a secure fit. We also kick off the construction of the brand new crane cabin, starting with the outer sheets and moving on to the internal frame. Even with a few challenges we’re making great progress, Kurtis dedication and skills keeps this project moving forward. Stay tuned for the next episode to see the crane cabin finish taking shape!

Missed any of the Franna Crane Project videos? Watch them all here: https://www.youtube.com/playlist?list=PLUzFN5xVei7UatVhlxlw3576rgwg2RTXf

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Making a MONSTER Hex Socket for a Hydraulic Nut Buster! | Shop Made Tools

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:38:17 GMT

We’re taking a chunk of solid steel and high tensile plates and transforming them into a custom hex socket, designed to torque up giant nuts for cylinder rods on a hydraulic nut buster. This isn’t your average DIY tool, we’re diving deep into the world of metalworking, using precision machining, milling and welding to create this robust and hefty piece of tooling. From the initial machining of the weld prep to the final touches on the milling machine, every step is captured in detail. We'll guide you through the process, from drilling and boring to welding and finishing, as we shape this raw material into a powerful tool. And then the final test, to see how the huge nut fits in the socket and how this tool looks in the hydraulic nut buster! 💪🛠

In this video we are using:

Hafco 261260G Centre Lathe
Hafco BM-63VE Milling machine
WIA 500i Weldmatic welder

Check out all of our Shop Made Tools videos here:
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Finishing the HEAVY FABRICATION On The Front End! | Franna Crane Project | Part 25

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:37:43 GMT

Witness the next phase of our epic Franna crane transformation! In this video, we dive deep into completing the heavy fabrication on the front end. Watch as we craft a custom door frame and cut out a window for the new cab. We also have a brand new pit cover plate and secure that in place by welding on stand offs, drilling bolt holes and then bolting in position. We also cut out the clearance holes for the headlights by using our trusty oxy-acetylene torch. But wait, there's more! We experiment with a custom nudge bar, though it isn’t quite cutting it, so we'll have to go back to the drawing board once more to perfect its look. As we piece together the fabricated components and position the tyres, the cranes new look starts to emerge. You’ll be amazed at how different our crane has become, it’s no longer just a Franna, it’s a custom work of art and testament to the ingenuity and hard work that happens here at CEE!

Missed any of the Franna Crane Project videos? Watch them all here: https://www.youtube.com/playlist?list=PLUzFN5xVei7UatVhlxlw3576rgwg2RTXf

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The SHOCKING State of This Rental Excavator! 😩| Repair BENT and BROKEN Parts 🛠

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:37:08 GMT

This Hitachi excavator has seen better days! Despite being a relatively new machine, it returned to our customer from a careless hirer covered in mud and with extensive cosmetic damage. We start by assessing the damage, which includes bent track frame steps, damaged blade lift cylinder guards, and a damaged toolbox and support plate under the back of the machine. We also quickly discover 2 broken bolts and a missing spacer plate that also need sorting out! Despite the damages, with Kurtis’ many years of experience and the right equipment to handle the job we remain confident that we can save our customer a significant amount of money. In this video, we'll dive into each process, from cleaning the mud-covered machine to straightening the bent metal using our hydraulic press. We’ll also be gouging off and then welding on the straightened track frame steps, not to forget making a new spacer plate and removing the broken bolts. This isn't just a repair; it's a rescue mission, join us as we transform this mistreated machine back to its former glory!

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Upgrades to the Zayer Milling Machine! | New Chip Guards and Installing DRO | Workshop Project

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:36:36 GMT

We’re tackling some long-awaited upgrades on our trusty Zayer B3500 milling machine. We're giving this beast some TLC, starting with those mangled chip guards at the back – they've seen better days. So, we'll be removing the old ones, drilling some holes in their replacements, and giving them a fresh coat of paint to match the Zayer blue. But that's not all! We've also got some new removable guards for the front of the bed, making sure everything stays clean and protected during those epic milling sessions. Plus, we say goodbye to that frustrating digital readout – we're installing a brand new, state-of-the-art Measumax MX-30i DRO for precise and reliable measurements. And because we can't resist improvements we’re planning for future projects and casting a keen eye over the mill for anything else that needs some love. We're thinking new way covers (replacing the old ones or maybe even making our own!), some fresh way wipers on the ram for a smoother operation, and maybe even some custom-made aluminium hand wheels to replace the plastic ones that could fly to pieces. Join us as we tick off another workshop project to keep this Zayer machine running smoothly for years to come!

Check out all our Zayer videos here: https://www.youtube.com/playlist?list=PLUzFN5xVei7XKeIvPNLxUfGQZ0GBE8kDv

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Building a FUME EXTRACTION System for Metal Arc Spraying! | Shop Made Tools

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:36:05 GMT

Ever wondered what it's like to build your own industrial-grade fume and particle extraction system? Well, we did! We started from scratch with some pressed sheets and a whole lot of DIY enthusiasm and turned it into a powerhouse capable of handling the intense fumes generated by our Metal Arc Spray machine! Watch as we construct the main body, deflector shield, and filter box, all welded together with precision. We also build a sturdy frame to support the entire system. Once it's assembled, we give it a fresh coat of paint and add the finishing touches, including castor wheels, extraction fan and filter. The moment of truth arrives as we test our shop made extractor with acetylene smoke and then put it to the ultimate test against our Metal Arc Spray machine. Will it effectively capture the particles and extract the fumes? Tune in to see the results!

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Forklift Cylinder Repair but We DIDN’T Expect THIS! 😱 | Part 1

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:35:26 GMT

We thought this would be a breeze – replacing seals in a 10-tonne forklift steering cylinder. WRONG! ☠️ Upon disassembly, we discovered a terrible sight: major DAMAGE on the piston and inside the barrel! 😱 This wasn't a simple seal job anymore – it is a full-blown rebuild! In Part 1, we dive deep into the damage, stripping the cylinder bare and removing all the seals. We then prepare for a new barrel by machining off the old mounts. We also tackle the task of repairing the damaged piston on the cylinder rod. We carefully machine it down, weld on silicon bronze, and then machine it back to spec. Don't miss Part 2 where we complete the rebuild with more machining, welding, drilling and honing! Subscribe to our channel for more of our jobs and projects!

In this video we are using:

MetalMaster HPM-150T Hydraulic Press
Hafco TM-26120G Lathe
-WIA Weldmatic 500i welder

WATCH NEXT Part 2: https://youtu.be/r0MKH8_2RDY

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Heavy Equipment Repair on HUGE Cat 992K Loader Cylinders! | Machining, Welding, Honing

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:34:59 GMT

Dive into the world of heavy equipment repair as we breathe new life into two massive Caterpillar 992K Loader lift cylinder barrels. Watch as Kurtis's expert skills and our innovative shop-made tools work together to transform these damaged parts. We start by setting up the first barrel in our Zayer bed mill to machine out the bore of the eye. Then we use our new shop made welding stand to set up the portable Sir Meccanica WS2 machine so we can bore weld the eye. While that's welding, we get the 2nd cylinder barrel set up in our Sunnen HTA-4100 horizontal honing machine and do a quick roughing pass before changing to finishing stones to add the signature cross hatching to restore the inner surface. After the eye has cooled down on the first barrel, we finish machining it to spec using the Wolhaupter boring head before facing and chamfering each side of the eye. Then it's time to change out the hydraulic cylinder barrels and do the process all over again. Another job successfully completed, thanks in part to our growing arsenal of shop-made tools that make these complex repairs more efficient and enjoyable. Join us on this video into the world of heavy equipment repair, where precision engineering and innovative tools combine to bring these industrial giants back to life!

In this video we are using:

Zayer Bed Mill
Sir Meccanica WS2 Portable Line borer
WIA 500i Weldmatic Welder
Sunnen HTA-4100 Horizontal Hone

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DIY Welding Upgrade: A Game-Changer for Our Workshop! | Shop Made Tools

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:34:31 GMT

Get ready for some serious metalwork - we’re taking our portable bore welding to a new level! And we also had a very special guest, Adam Savage from @tested and @Mythbusterstvshow drop in to visit!

In this video we are making two heavy duty stands for our Sir Meccanica portable line boring and bore welding machine. This will allow us to do even more internal and external welding on jobs more efficiently. We'll start by machining precision bearing mounts, then assemble and weld together the sturdy frames. While the welds cool, we'll finish the bearing mounts and get them ready for action. With everything complete we assemble the big stand and mount the Sir Meccanica machine to make sure everything goes together correctly. Now we can test it out on a real-world job: reclaiming pins on suspension strut caps off a Caterpillar 777 truck. Watch as we tackle this workshop project head-on and see how our DIY welding station saves time and boosts efficiency.

Check out all of our Shop Made Tools videos here:
https://www.youtube.com/playlist?list=PLUzFN5xVei7VnqB59w-gVlWGPeT7we5uF

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Official CEE Merch shop: https://www.ceeshop.com.au

Check out our CEE Amazon store and explore our favourite finds that we use in the workshop:
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The Final Build & Ultimate Test of Our HEAVY DUTY Tool Post Grinder!

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:34:00 GMT

In our final episode of this exciting build, we bring our heavy duty tool post grinder to life! Watch as we connect the VFD, conduct a test run, and then disassemble before drilling and tapping the mount for lifting bolts. After a fresh coat of paint, we reassemble the tool post grinder and get ready for the moment of truth. Before the big demo, we ensure precision by truing and dressing the grinding stone using a diamond dresser. Then, we put our grinder and external spindle to the test by grinding a piece of 4140 high tensile solid bar. But that's not all! We also showcase the versatility of our grinder with our impressive extra-long internal spindle. This project and build has been very enjoyable and we're looking forward to putting it to work!

MISSED ANY VIDEOS of making the tool post grinder? Watch here: https://www.youtube.com/playlist?list=PLUzFN5xVei7We1fjeizxX4NBPWE08WvBm

#ToolPostGrinder #DIY #Workshop #Metalworking #Build #Engineering

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Making a HEAVY DUTY Tool Post Grinder! | Part 1 | Shop Made Tools

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:33:32 GMT

We’re levelling up our lathe game and crafting a heavy-duty tool post grinder from scratch! In this first part, we're building a sturdy and reliable mount that will fit perfectly onto the top slide and serve as the foundation for our tool post grinder. Starting with steel plates, we'll show every step of the process of transforming them into a precision-engineered component. Our build begins with a large base plate and we use the lathe for drilling and boring the details for the mount to fit securely on the top slide. Next, we move to the milling machine for drilling and tapping holes in the plates that will become the spindle clamps. With the groundwork laid, we assemble the plates and weld everything together. Finally, to ensure the clamps are perfectly aligned and centered, we utilize the lathe for line boring, a process that guarantees concentricity and precise fitment for the spindles that we’ll be making in part 2! Whether you're a seasoned machinist or a DIY enthusiast, this build will be sure to give you some inspiration!

In this video we are using:

Hafco TM-26120G Centre Lathe
Hafco BM-63VE Milling machine
WIA 500i Weldmatic welder

Check out all of our Shop Made Tools videos here:
https://www.youtube.com/playlist?list=PLUzFN5xVei7VnqB59w-gVlWGPeT7we5uF

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We upload new videos every Friday at 5pm AEST! If you want to see more of our videos click LIKE & SUBSCRIBE! You can subscribe to our channel here: https://bit.ly/ceesubscribe

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Official CEE Merch shop: https://www.ceeshop.com.au

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Unbox & Testing WORLD’S MOST INNOVATIVE Metal Spray System! | NEW Metallisation i450 Arc Spray

(YT)Cutting Edge Engineering — Sun, 15 Feb 2026 05:33:02 GMT

Ever wondered what it's like to unbox the future of metal spraying? Join us as we had the opportunity to get our hands on the brand new i450 '22 series' Arc Spray system made by Metallisation Ltd in the UK! This isn’t just any metal spray machine; it’s the world’s most innovate arc spray technology currently available. We have a couple of expert techs from Metal Spray Supplies Australia in our workshop to help unbox this beast and walk us through the setup process, step-by-step. But we’re not just showing you the shiny new machine; we’re diving deep. From initial test run to a full-blown demonstration on a larger piece of material, we’re putting this system through its paces. We show the prep work, the spray process, and then the finish machining. If you're in the metal spraying game, or just curious about cutting-edge tech, this video is a must-watch. Get ready to be impressed!

A shout out and special THANKS to our supplier Metal Spray Supplies Australia for all their support with organising, setup and installation and also thank you to Metallisation Ltd for allowing us to unbox and test this new setup!
https://www.metallisation.com/
https://www.metalspraysupplies.com/

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We upload new videos every Friday at 5pm AEST! If you want to see more of our videos click LIKE & SUBSCRIBE! You can subscribe to our channel here: https://bit.ly/ceesubscribe

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Official CEE Merch shop: https://www.ceeshop.com.au

Check out our CEE Amazon store and explore our favourite finds that we use in the workshop:
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#australianmachinist #machineshop #machinist