The use of crusher backing material in your engine block filling application is an excellent use of this product. The minimal shrinkage incurred with this material under the cyclic heated and creepage prone atmosphere a cast engine block endures, makes the use of this kind of hi-density epoxy, as good a choice as it gets. Personal experience with this material in that application is fairly extensive. Having raced supercharged gas, nitro & alcohol dragsters for 30 years, filling blocks was part of the drill. I’ve used this type of epoxy material as far back as in the late 60’s, in cast iron 392 C.I. fuel Chrysler A-1 blocks, to support cylinder walls. Prior to the advent of billet aluminum cylinder heads, for K-B type Hemi’s, crusher backing material was used to fill cast iron Mopar type heads and the first cast aluminum heads like stage V’s. The late Hemi type heads had a propensity towards cracking between the seats and from the seats through the exhaust ports. The fix was to weld the cracks and fill the heads with crusher epoxy, in order to support the combustion chamber. That’s where the propensity for minimal shrinkage of the material became very apparent. The back, or water side of the cast head combustion chambers gets a lot of heat and the crusher backing material responds to that with excellent properties.
A later use of the product came about in stopping the potential water leakage in preparing 400” small block Chev’s to accept 4.000” stroker cranks. The bottom of the block was filled with the backing material to the low soft plug hole and water drain holes cross drilled to use the stock drain plug holes in their intended manner, as well as a ¼” N.P.T. source for external water plumbing. The crusher backing material works well in that atmosphere of heat and prevention of water leaks through grinding through the block for stroker clearance. As far as this material providing enough strength to drill and tap for head stud installation, I’d say, no on its own. However if you needed to drill thru the deck for stud clearance while still relying on the deck for primary thread strength, you could drill and tap this material. Easier way to accomplish your need for through deck stud clearance, would be to install the stud with heavily greased threads, intended as a release agent, through the deck. Pour the backing material, letting it catalyze, then remove the stud and you’ll have your necessary clearance to properly install your head studs.
Your need is an excellent application for this material. Your easiest source of obtaining our product or something similar would be from Compass Equipment, in Oroville, CA. Tele 530-533-7284.

The stationary jaw gets more of a rubbing and gouging action against it than does the moving jaw. This is due to the moving jaw's tendency to push the crushed material against the immobile frame side of the crusher. This same rock will roll somewhat against the moving jaw, resulting in lesser rubbing or gouging action.
Typical wear ratios between the stationary side and the moving side are 2:1 stationary wear. This higher wear rate on the fixed side is true with cone crushers as well, though there we've found that the ratio of bowl liner to mantle wear normally runs between 1.2 and 1.5:1.
In both types of rock crushers you'll see design exaggerations to the fixed side in an effort to even out those ratios. That's so that service related maintenance can be carried out at the same time to both sides of the crusher.

Absolutely --if you have a crusher with a set of worn cone liners you would like to review, for improved output, or service life increase, you can contact your closest Columbia Steel district manager. He will make arrangements to come to your site and measure the worn profile of a set of recently expended and removed liners, that have operated under the conditions for which you are looking for a liner improvement. We’ll identify your operating conditions and we’ll prepare a wear study of your parts with a proposal offering a service guarantee to go with the price and delivery quotation.
There’s no need for you to go to the effort of cutting these things up. Wear studies of these parts are part of our customer service. We’ve found that simple section thickness measurements are the most efficient means of obtaining wear profile data. Others have attempted more sophisticated means of obtaining the dimensional values, using expensive devices. We’ve deemed simple accurate uniform thickness measurements to be adequate (easy to hold to within .060”). The name of the game is to make an accurate interpretation of the dimensional values obtained, not in how they’re measured.
Contact your local Columbia Steel district manager and he’ll take it from there. If you don’t know who your district manager is, then contact Columbia Steel customers service at 503-286-0685 (service@columbiasteel.com) to obtain this information.

There are several manufacturers of roll crushers that use roll shells in the range of the 55.118-inch diameter you note, and any of these manufacturers’ parts could have been used in the fabrication of your machines. The manufacturers and sizes of this kind of common roll crusher are as follows (in all cases the first numbers represent the outside diameter of the machine, while the second numbers define the width, typically in inches):

Cedarapids made a 55x30 model
Krupp makes a 1.4m x .8m machine
Pioneer Engineering made a 54x24 model
Traylor Engineering made 54x24 and 56x22 models
Universal Engineering made 54x24 and 54x30 models

Although all of these models share a common smooth outside diameter, each will have completely different inside diameter details. The seating locations, widths and machined angles will differ considerably. Some will incorporate internal anti-spin keying of varying means.

While they look similarly simple on the outside, the inside detail is more complicated. This leads to the difficulty in identifying which one was used in designing your machines. If the roll shells used weren’t identified clearly elsewhere, the only source of proper identification will be cast in the part on the inside, usually somewhere between the mounting seats. There’ll be a parts number and manufacturers name on the part in either raised or recessed letters.

You’re dealing with $20k to $25k per piece parts here, so care will need to be taken with the identification process, and disassembly will be required to obtain this information, if it’s not recorded elsewhere. With the silica material you’re processing, use of a high hardness alloy steel or iron may be in order, rather than conventional manganese parts for optimum service life. We’ve had considerable experience in the manufacturing and application of roll shells in more unusual applications.

In regards to the consultant end of your question -- without knowing the specific area of expertise you require, you’d likely do well there in Mexico, by contacting Aggregate and Mining Supplies de Mexico, located in Irapuato, Mexico. They may be able to offer you direction on that subject. Thank you for your inquiry.

Getting a jaw crusher to wear the ends off properly is similar to finding the proper match point on a set of cone crusher liners.

The jaw crusher was designed around an ideal closed side setting (C.S.S.). Deviation from that position diminishes the totality of jaw end wear. A hook forming on the stationary tells us that the crusher is being run at a closer C.S.S. than it was intended.

Whether that's right or wrong, it is what it is. We've altered and made special end details on many movable and stationary jaw dies, by either lengthening or shortening, to correct chronic match point issues. Length of the toggle plate and range of adjustment of the crusher affects the way the jaws align at the discharge end, as much as the way the material being crushed is reduced. If lower jaw mis-match occurs enough to affect output rate, try to correct with toggle plate and adjustment settings. If that doesn't fix things, a special length jaw can be made.