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In Reply to: Idler Repair posted by H2 on Tuesday, September 18, 2007:
I work at a cat dealer and one of our branches specializes in undercarriage work. They weld up all idlers for reuse. There is a machine that slowly turns the idler while welding it. It ends up being one continuous weld on each side and doesn't require any grinding afterward.
I guess you could do it by hand if you were a good welder.