Modifying a Hydraulic Cylinder

[boustany]

A while back I asked a few questions about hydraulics so I could control the chute deflector of my snowblower to hydraulic (vs. manual) operation.

My problem was that the most suitable cylinder I could find was 4" too long and had 1" of extra stroke.

So I decided to try modify it. Hey - it was only $135 for the cylinder, and I need more paper weights). /forums/images/graemlins/crazy.gif

I documented it. I have about 10 pictures to post, so please let me finish before makin fun.


First: here is the problem: cylinder too long

 

[boustany]

and here is the cylinder all taken apart like

 

[boustany]

I cut the end off with a cut off saw, and tried a test weld to a piece of mild steel, hoping against hope it would weld

 

[boustany]

It did! So, I made a jig to hold everything square and close long enough for me to put a 1/8" tack.

 

[boustany]

Unfortunately, the photo of the jig I set up for the test weld was out of focus, but I took a piece of copper piper over the cylinder rod to protect against splatter.

After a few tense seconds of MIG welding (flux core) and frantic wire brushing, this was the result.

And I'm not even a talented welder!

 

[boustany]

Here's a close up

 

[boustany]

This is what it looked like after I put everything together.

I put a 3/4 brass bushing on the rod to limit the stroke. Later, I replaced that with a 1" bushing. The ID of the cylinder is 1", and the shaft is 5/8" so I used a 7/8 x 5/8 bushing.

 

[boustany]

This is how it looked with the cylinder in the 'out' position (deflector down) after the mods

 

[boustany]

and finally, here is what it looks post modification with the cylinder in the 'In' (deflector up) position.

I checked the cylinder after the mods and it works 100%

(That was the last picture)

 

[beenthere]

Looks like a very good weld.
What was the size (retracted length) you started with and what was it when you finished?
Appears you didn't change the outside cylinder, but cut off the inside rod? What was the extended length?