It’s unbelievable. A broken axle can actually be repaired. The secret lies in using mortise and tenon joints. This is a tractor owner. His axle broke unexpectedly. But new parts are unavailable in Pakistan. In this tricky situation, he had to find a repairman. The axle is made of high hardness steel. The first step is to heat it. This reduces the hardness, making it easier to work with. Next, the broken flange is fixed on the chuck. The lathe’s tailstock is used to restore the axle. The repairman carefully measures the axle’s data for reference during the repair. He operates the lathe to cut the broken section. Although this shortens the axle, the repair must be based on a flat surface. Only then can the repair be successful. The end face is machine to be very smooth. But this makes the overall length shorter. To restore the original length, the repairman drills a hole in the axle. The hole serves as a reference for concentricity and is key to extending the material. Using a twist drill, the hole depth reaches the repair standard. To balance the diameter and depth, the hole is expanded with an internal boring tool. This ensures even internal stress. With the internal boring tool, the material can now be extended. However, the axle must withstand high torque. So the repairman modifies the flange. Using the lathe chuck. He rotates the milling cutter creating a groove on the edge. Even without a milling machine, the repairman Cleverly adjusts the tool holder to achieve the milling function. This groove is crucial for connecting the shaft. The repairman selects a piece of copper round steel to extend the broken flange. With the hole diameter determined, the round steel must be cut into a small cylinder to fit into the hole. But this time a mortise and tenon structure is added. A step is machined on this basis. For the other side needing repair, the repairman cuts and trims the round steel using a threading tool for fine adjustments. The round steel is cut into two flat planes to fit into the groove. After comparing with calipers, the other layer can be replicated. Next, the two parts are assembled. A hammer is used to apply pressure during assembly. For better welding, the joint is beveled. This is the only way to enhance welding strength. The welded round steel becomes part of the flange. Considering a bearing needs to be installed on the axle, the repairman removes the welding slag. But the broken spline end still needs to be connected. The head is machined into a small cylinder again to ensure no errors after assembly. The entire process takes just a minute. Now a hole can be drilled. After the hole is machined, without a high end hydraulic press, they use a hammer to drive it in. Despite the physical effort, the repairman doesn’t give up. After measuring and comparing, it’s clear the overall length hasn’t changed. Then, using welding Rods the bevel is fully welded. The threading tool smoothes the weld. After removing the rust from the flange, the axle repair is complete. The repairman’s skills are truly amazing.