SNS 157 Part 2: Failed Repair on Roll Journal

This is a recent job I had to tackle. It's a large roller for a local industrial facility, and one end of the roller has a damaged shaft. It was previously repaired by someone else and that repair failed.
I'll show you the failure and then proceed to fix it my way. We'll show some machining, tapping, and stick welding to get this roller fixed up and back to the customer.

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