How to Machine This Part

[ddickey]

A friend at work asked if I could machine a new handle for this super old clamp I think it is. I know he's got an old manual drill press that needs fixing but this looks like a handle from a clamp.
I think the end on the screw can be pressed out but not sure how to get the handle off. Thinking this must be cast iron. He wants it remade in cast iron which I'm not to excited about but said I'd think about giving it a shot.
Any ideas how to go about it?

 

[benmychree]

Likely best to braze or cast iron (torch) weld it. It would not be easy to recreate it so as to look original in cast iron, except by having a pattern made and casting it in iron.

 

[WarrenP]

Yes, I agree best idea would be to weld it back together.

 

[GL]

May try high Nickel stick weld rod also. Local weld supply should be able to hook you up.

 

[ddickey]

That's what I was thinking also.
Thanks guys.

 

[Eddyde]

Welding cast iron is tricky, if not done properly it can cause cracks to start elsewhere on the part.
Preheat the parts and any metal contacting them, work table, clamps etc. Use an acetylene or blowtorch, get it around 800f. After the weld allow the part to cool slowly, you can hit the part with the torch again and slowly back off or cover it with dry preheated sand.
30 years ago, I did a similar weld repair on a cast-iron foot pedal for a vintage dentists chair, its still in one piece.

 

[GunsOfNavarone]

I'd TIG weld it with silicon bronze. It's lower welding temp and bonding excellent with dissimilar metals would make it a good canidate.

 

[Cadillac]

Or make one out of steel. Then tell him the reason not to make out of cast is this very situation. It breaks. Reuse handle can shape a lot of it with hand grinder and flaps to take edges off. Just machine the lug ends circular with holes and grind the rest.

 

[ddickey]

I'll ask him about that.

 

[GoceKU]

I agree easiest way is to weld it and use hand files to smooth back the weld. Other way is to have it cast in steel or start with a square piece or steel and mill one. You'll also need a rotary table for the ends and couple of round end mills, but it can be done.