Stillion Industries and Electro Arc 3 year update

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Stillion Industries was closed down for nearly a month in 2020 due to Covid-19.  This was a huge blow to our business less than a year after purchasing Electro Arc Manufacturing, the original Metal Disintegrator manufacturer.  Based in Ann Arbor Michigan since its inception in 1947, Electro Arc has been a top US producer for metal disintegrators worldwide.  By joining forces and continuing the legacy established by Electro Arc, Stillion Industries is providing top-quality machining services and its lines of products. We are still recovering from the loss of customers, changes in supply chain, and product availability. As a local manufacturer for the Washtenaw county local community, Stillion Industries has been dedicated to supporting fellow local businesses in our 50 years of business.  We source as many items locally as possible, if not in the southeast Michigan area, then from the United States. Chuck Stillion, the founder of Stillion Industries, and Keith Stillion, the current owner are both dedicated to supporting the local community. Stillion Industries often provides discounted services to local farmers. We are grateful to our hardworking employees who have continued to work with us through this difficult transition.  We understand that many people’s lives have been changed forever and that includes the lives of our employees and owner. Long-time Electro Arc employees Tim Kinser and Doug Peterson retired in 2022. In addition to providing their line of Metal disintegrators, Stillion Industries is proud to manufacture the Ames line of portable hardness testers.  You may choose to purchase any of the Ames products online or give us a call to determine which product is best for you. Stillion Industries has been working hard to improve these products and the customer experience. This year, Stillion Industries celebrates 75 years in business and Electro Arc turns 75! In late 2021, Shadow our shop cat went missing which was very sad for all of the staff. After months, and assuming the worst, Keith agreed to get new shop cats for pest control. We welcomed two kittens into the shop in March 2022 and named them for our product lines: Ames and Electro. Much to everyone’s dismay, Shadow showed back up to work this spring and was not happy to find her little replacements. They have managed to coexist, but they are not friends (Shadow won’t allow it). You may have noticed that we have made a number of updates to our online presence in the last 3 years. The Stillion Industries website just underwent its second major redesign, both Electro Arc and Ames websites experienced some serious problems as we returned from the covid shutdown, and we hired a full-time marketing person to redesign and maintain the websites as well as manage our social media and online presence. You will notice more products available for purchase online, including Electro Arc accessories. Every website has a chat feature so you can reach out to us during our business hours. We have also added more contact forms for ease of contact online. We also added a new website as a resource for Electro Arc machine owners. Metal-Disintegrators.com

Using a Metal Disintegrator for Off Road Applications

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Heavy-duty equipment and machinery is classified as “off-road”, these massive vehicles are necessary for development, as a key component of infrastructure, things must be moved and lifted quickly and accurately.  Excavation for development or discovery sends us miles into the earth to discover and build. Innovation is upon us and we rely on off-road machinery like dump trucks, excavators, and cranes to take us there. When using off-road equipment in construction, mining, agriculture, and marine fields you need high-quality, long-lasting, and powerful tools to keep your machines running.  Tabletop Metal Disintegrators are great for Large Parts: You can use our large tabletop metal disintegrators to remove broken taps and drills in engine blocks, heads, and power trains. Besides broken tooling, broken 10MM (3/8″) exhaust manifold studs are disintegrated and the old threads are cleaned in three and a half minutes. You will want to use our largest tabletop metal disintegrators for jobs like these. The model H-K6VQT (referred to as the “Tap Zapper” in the past) features our IQ head which can handle small and up to 2 inch/50 mm diameter in one pass.  Standard with a 30-inch workspace you can request a custom tabletop. The model HK-10QT also features the IQ head and comes with a 20 KVA power supply for extra power.  The huge table is 46 by 25 inches and has a capacity of 8000 pounds with customizable table options as well. The Auto-Feed feature allows for hands-free operation and minimal electrode consumption for long-lasting use. and the ultimate 10SG are often used Our Portable metal disintegrator unit line includes 2SQT which can be used to remove large and small broken taps and bolts in hard-to-reach places. Perfect for extremely large castings like the arms of bulldozers or radiator housings on the D10. Electro Arc Metal Disintegrators are a tool for you to reduce waste. Remove broken taps and drills in minutes with little effort while leaving the original hole and threads intact. The Electro Arc process: Use our durable Metal disintegrators to remove broken rear wheel studs from large dump trucks quickly. Save customers thousands of dollars in just a few minutes with the Electro Arc process.  Clients like Bobcat, Komatsu, Volvo, Caterpillar and John Deere have experienced the benefits of our metal disintegrators for off-road applications

How can you remove dowel pins?

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If you are in any type of manufacturing whether you use metal or wood, chances are you have encountered some type of broken fastener in your line of work.  You may have encountered broken bolts, broken taps, broken screws, broken pins, or broken dowels.  Today we will discuss removing broken dowel pins. See Dowel Pins Removed with an Electro Arc Metal Disintegrator: As you probably know if you are reading this article, dowel pins are solid, headless cylindrical rods most often used in conjunction with socket screws. You may also be using dowel screws or dowel pin reamers. Dowels serve many functions they can ensure you put the gasket on correctly and hold the gasket in place.  They also serve to align and prevent “walking” on heating and cooling cycles. Chances are if you work in the manufacturing industry, or you may work with automotive, farm, aviation, construction, or other industrial equipment you work with dowel pins in some facet. You probably also know the headache associated with a broken dowel.  You may be here because you need help getting a broken dowel pin out of a camshaft, need to know how to remove a broken steel dowel pin, or maybe you are wondering how to extract a blind/broken dowel pin from a flywheel. Whatever the case we know that a dowel pin may fail after many years of service as they tend to get brittle. In the Below Example, a Pin is Removed Using A Metal Disintegrator: The hardness of the broken metal dowel pin is a key factor to ease of removal and time spent in the process.  You are likely working with a work-hardened metal. If you are working with a drill, removing a broken dowel pin may take hours.  Not to mention, you will dull your drill in the process. If you are removing a broken dowel in a hole, you will have to replace the dowel.  The process of removing the broken dowel will likely destroy it.  Using heat and cold processes may be successful in removing your broken dowel, however, this process requires very accurate timing and great care to ensure only the dowel is affected. Manual removal of a stuck dowel pin If you decide to manually remove the dowel pin, this could be a lengthy process and will likely ruin the dowel pin.  If you are removing a broken dowel pin from a block you have several options.  You may choose to heat the block around the dowel and use vice grips to remove the broken dowel pin.  If that doesn’t work, you should be able to drive them out the back using a 5/16 bolt that is just long enough to reach the dowel from the back side then hammer the bolt.  A more complicated option would be to use a Dremel to notch the pin on the sides, then drill a hole in the top.  You must be careful not to weaken the pin by removing too much of it because it will break.  Then you will need piano wire and a crescent wrench.  Loop the piano wire through the center while holding the flattened sides with the crescent wrench wiggle to remove. So what if you don’t have several hours to dedicate to the removal of your broken dowel pin?  Removing a broken dowel pin manually can add hours to your billing. You may not have the additional time or budget to dedicate to this tedious process, especially since it destroys the dowel pin anyway. Electro Arc’s products are designed to remove broken screws, bolts, and drills in minutes. Our metal disintegrators have been getting the job done in minutes for 75 years!

How Covid Changed Stillion Industries

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https://youtu.be/PsykXjx33PM 2020 was a difficult year for most businesses, especially in manufacturing.  Covid-19 has changed everything from how we communicate to how we work and live. Now two years later, we are still experiencing difficulty with supply chain issues and the economy has created the necessity to raise our prices. We are so appreciative of, all of our staff, community support and the ability to continue offering products and services.  We also appreciate all of you and your patience during our downtime and with delays in fulfilling orders. While we did fall behind in production during the Covid-19 shut down we have found a new normal in meeting the needs of our customers.  The challenges we endured inspired improvements to our processes to minimize problems in the future. Another setback we experienced was problems with our websites for both Electro Arc and Ames Testers. Since then we have improved our websites and social media presence to provide you with updates and inside looks at the company and our products. We have also expanded our online shopping options to allow you to purchase accessory items for Electro Arc accessories in addition to the Ames products that have been available to purchase online for some time. Improvements to the websites include a live chat, more resources for machine owners, and a 75-year retrospect of Electro Arc’s history. You may have also noticed our new machine builder which helps you determine which metal disintegrator can best meet your needs, allowing you to compare the 40+ custom metal disintegrator options that we offer and the advantages of those machines on Electro Arc sites. Try the New Machine Builder to Choose the Right Metal Disintegrator for your Application! Check out our Social media profiles and please follow us! Facebook Youtube Pinterest Linkedin Instagram Tiktok As you may know, the Electro Arc and Ames product lines joined our company in mid-2019.  We have since made improvements to the product lines due to the lack of availability of necessary components, obsolescence and to assist in efficiency.  We look forward to continuing to offer the reliable products associated with these brand names and producing these products in Michigan is our pride.  Stillion Industries has been offering Michigan based machine services for 50 years now, and Electro Arc products have been made in Michigan for 75 years.

Maintain the Highest Quality with Metal Disintegrators in Space Applications

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When it comes to Aerospace accuracy is essential.  You can count on our metal disintegrators to deliver accuracy in your industrial applications with aerospace production. Aerospace organizations may conduct research, design, manufacture, operate, or maintain aircraft and spacecraft.  The Department of Defense (DOD) and the National Aeronautics and Space Administration (NASA) are the largest consumers of aerospace products in the United States.  Due to strict guidelines, parts and repairs must be certified for use.  Electro Arc has experience with government contracts and all of our products meet the highest guidelines. Bolts and nuts may fail in aerospace applications due to a variety of factors. Higher-strength bolts which are harder, tend to be more susceptible to failure. Fatigue, fractures, and cracks can lead to bolt failure causing bolts to break. Vibration fatigue, corrosion, and fretting wear can result from temperature swings and load transmissions in the normal operation of aircraft and aerospace vehicles. As a time-sensitive and in-demand industry, there is no question why companies in these industries would want an Electro Arc metal disintegrator to assist with the replacement and repairs of broken bolt issues. If you are Manufacturing parts and equipment in the aerospace industry, you are producing massive vessels. When it comes to building space vehicles, airplanes, guided missiles,  propulsion units, and aircraft engines precision, quality, and consistency are required. Maintain the highest quality level by removing broken drills, taps, and rivets from production parts such as engines, wings, and landing gear with ease and speed. Electro Arc Metal Disintegrators will assist you in generating less scrap and sticking to your stringent timelines.  You will find Electro Arc metal disintegrators essential in maintaining your production equipment and aircraft by removing broken rivets and distorted or frozen bolts in minutes. You will probably prefer our Electro Arc model 2-S portable metal disintegrator for use in aerospace applications. Equipped with the mini-magnetic fixture it is perfect for use in hard-to-reach places. When you need maximum portable power, our newest model the Bolt Eater perfect for general purposes. Use this heavy-duty metal disintegrator to remove broken large drills, bolts, taps, and more on your production parts and prototypes. Electro Arc Manufacturing has a history of working with NASA, North West Airlines, Delta Airlines, and Boeing.

Stillion Industries Welcomes New Machines to the Family

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Stillion Industries made a major change on March 25th, 2022 when we sold our Mac turn and replaced it with a Space turn.  This smaller machine is more versatile for our needs and freed up a large amount of much-needed area on the floor for new machines to come to our shop.  Now in May, we are excited to announce 3 new machines that have joined the Stillion Industries arsenal!  The Devlieg Spiralmatic Jigmil 4B-72 Boring Mill now stands tall in our shop ready to take on any job we can hoist onto it!  The Monarch Model 612 lathe which has the capacity for pieces 128 inches long and a 31 inch swing.  One of our Employees who came to us from Pinnacle Engineering when they closed, shared his history with these machines including running a 2 ½ ton roller on this machine!  We’ve also added to our Bridgeport collection the Series 1. It took us about 3 weeks, but we have 2 of these machines up and running now.  The Boring Mill was used just today to do final work on one of our Electro Arc table tops.  In the future, we will be able to do all of the work our table tops need! These new machines provide a larger capacity for big jobs. We are also now able to do jobs in-house that we would have outsourced in the past including work on cast iron table tops for our Electro Arc metal disintegrators.

Stillion Industries one-time conversion for your disintegrating head

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Did you know that Stillion Industries purchased Electro Arc in 2019?  As you can imagine, with any new company purchasing another company there are a lot of new things to do and know.  The name Electro Arc is known worldwide as the world’s best metal disintegrator manufacturer.  This is because of the sturdy design long-lasting nature of this machine.  As with any good thing, we have made necessary improvements to the Electro Arc product line since we have taken over as the manufacturer.  We have created new boards for our Auto-Feed feature and we have been researching to design our own pump to replace the pump we use in the machine since this machine has been hard to find since we took over. Due to supply chain issues, we replaced a connector used in the vibration of your Arc-er disintegrating head.  This new part can be easily replaced and we provide detailed instructions to walk you through the process of upgrading your machine.  The new part number is A6113, for connector assembly, panel mount, Arc-er or Servo head vibration.  We will detail these instructions for you below, please read and understand them before you attempt any changes.  Do not make an attempt to make this modification if you are unclear or do not understand the instructions.  Consult with a licensed electrician if needed. 15 Steps to Install the New Pigtail Adapter For Your Disintegrating Head: Step 1 Turn off your machine. Step 2 Disconnect power from the machine (refer to your company’s procedure for lock out tag out if needed.) Step 3 Locate the ROUND 2 PIN connector on the back of your machine.  Note: your machine may have more or less connection points than the picture below.  There should only be a single two-pin connector. Step 4 Remove the Allen drive button head screws on the outer edges of the back panel of the machine.   Step 5 Locate the two wires on the back side of the existing panel mount connector.  Note: wire colors may vary based on the age of your machine. Step 6 Cut each wire roughly 2″ away from the existing connector. Step 7 Unscrew the nut and lock washer from the back panel to remove your old connector. Step 8 Insert the new connector into the existing hole and mark the 4 mounting holes. Step 9 Drill 4 places with a 9/64″ (3.6mm) drill bit.  A center punch may help keep the drill bit on location. Step 10 Install the 4 screws from the front face of the back panel and place a washer, then lock the washer and nut over the screw.  DO NOT overtighten, this will crack the plastic on the new connector. Step 11 Strip back the wires from the hardness inside the machine cabinet. Step 12 Connect the wires from the connector to the wires from the harness.  Polarity or color coordination does not matter for this.  A number of methods can be used so long as both wires are properly insulated from each other and from the machine cabinet. Step 13 Reinstall the back panel of your machine using the button head screws.  Use caution to ensure no wires are pinched during reinstallation. Step 14 Connect the vibration cord end from the Arc-er Head to the new panel mount connector. Step 15 Reconnect power to the machine.  Consult your company’s lock out tag out procedure if needed. If you have any questions about the installation of this new pigtail assembly, please contact Cody for Technical support on Electro Arc’s main line, his extension is 105, or email crobbins@electroarc.com

Stillion Industries is Celebrating 50 years of Business

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When you hear the name Stillion, the first thing that should come to mind is Stillion Industries.  A southeast Michigan machine shop that has been providing service in Washtenaw County for 50 years this year!  A family business, you can count on Stillion Industries to provide the highest quality machining work.  Chuck Stillion started this small business in Ann Arbor on Dino Drive.  The company was passed from father to son in 2006. Stillion Industries expanded its operations by purchasing Dexter Manufacturing in 2013.  Again in 2019 by purchasing Electro Arc, a metal disintegrator manufacturer also based in the Ann Arbor area.   Electro Arc was a client of Stillion Industries machine shop for years before the company went up for sale and Keith Stillion decided to purchase it.  With the acquisition, we gained both the Electro Arc metal disintegrator product line of over 40 bespoke machines as well as the Ames product line of fine precision hardness testing instruments now machined in-house. Electro Arc is also celebrating a big anniversary this year.  75 years of Michigan-based design and innovation which has become an asset to industries worldwide!  Under the Electro Arc name, Ames Portable Hardness testers have also been manufactured by Electro Arc since 1975.  These two tools are dependable not only in name but in reputation as well.   Like Stillion Industries’ machining work, Electro Arc machines are built to last.  This makes the two companies a perfect complement to each other.  We take pride in the new Electro Arc products we now produce and strive to make them better so you can count on these machines for years to come as large and small shops worldwide have in the past. To celebrate this special double anniversary, Stillion Industries had an oldest machine contest in an attempt to make connections with old Electro Arc machine owners who are still running metal disintegrators made by the company in the 60s and 70s!  While the design has changed very little, the look of these machines has changed over time, you may see them with different cabinets or colors like green and blue!   With proper maintenance, these machines can last a lifetime!  As an Electro Arc machine owner, you can count on us for your machine maintenance, repair, and upgrade needs.   Every machine we sell comes with a one-year warranty.  Another promotion we are offering to celebrate is the model 1 Ames Portable Hardness Tester in its old wooden case.  This limited edition product is only available while supplies last!  We continue to offer repair and calibration services for testers with a model number of 12000 or newer.

Why you need a metal disintegrator in Manufacturing

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General manufacturing covers all goods made in production for use or sale using labor and machines, tools, and chemical or biological processing.  This field including hand-crafted and high-tech production is most commonly associated with industrial design which consists of raw materials from the primary sector of the economy being transformed into finished goods. Manufacturing of industrial goods internationally is an aggressive market. The state of the financial market and availability and condition of raw materials dictate how the manufacturing industry will perform annually. Manufacturers who compete on a global scale must maintain optimal output while reducing any halt in their assembly in addition to meeting expectations for price and quality of goods. You can use Electro Arc Metal Disintegrators to repair and maintain your equipment and parts with minimal output of leftover material. Remove broken taps and drills quickly and efficiently, leaving the original hole and threads intact every time.  Use your Metal disintegrator in production maintenance, and repair your equipment by removing taps and drills in minutes. Electro Arc Portable AC model 2-S Metal Disintegrator: A variety of Electro Arc models may be suitable for your application in general manufacturing. Our model 2-SE tabletop metal disintegrator has a single-arm superstructure and a moderate 457 x 457MM (18″ x 18″) worktop. Just like our model 2-S with a small tabletop and cross-arm to provide you with a mobile work surface for small parts.   Standard with the Arc-er disintegrating head, you can upgrade to the IQ head on our model 2-SQT for larger range. Alternatively, you may prefer the fingertip controls and ease of head positioning which allows for quick setup with our Model 2-DVQT which features a vertical-plane double barrel superstructure for rigidity and an 813MM x 813MM (32″ x 32″) worktop. Portable models like the 2-S are attractive in many workplace conditions which have limited space.  You will find the portable models provide the customizable power and execution you need in a compact and portable unit. You can mount the head on your Bridgeport, drill press, lathe or even a mill in a flash. The Electro Arc Model 2-S can be used with a CNC machine, Bridgeport, directly on your workpiece, with a radial drill or lathe. Past clients of Electro Arc Manufacturing Company were Sandvik, a multinational engineering group. With operations in tooling systems including metal cutting, and Also providing technical solutions in mining and rock excavation.  Whemco, a worldwide supplier of heavy industrial components for power generation, mining, metals, and the shipbuilding industries. As well as the Timken Company, a global industrial leader in engineering bearings, and power transmission product brands.

The birth of Metal Disintegrators by Electro Arc

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As Stillion Industries and Electro Arc celebrate dual anniversaries, a lot of research has exposed historic information about our Electro Arc line of metal disintegrators and the company. An accidental discovery of carbide impregnation through EDM had been untapped in the metalworking industry despite the discovery in the 1940s because it was such a new process operator error was leading to problems. Electro Arc was one of the pioneering companies that changed the market by developing their line of Metal disintegrators.  Through the use of carbide impregnation, great success was found with use on hard metals such as drills, lathe turning tools, and taps. In July of 1971, Electro Arc’s carbide-impregnating machine was mentioned by the Machinery magazine discussing the promise of carbide impregnation.  The article mentions Spalding using the Electro Arc model F-5 machine to impregnate dies and punches extending the life of their tools considerably.  It also mentions a California manufacturer who recovered the cost of their machine in just two months by extending their drill life by 10 times. Electro Arc Carbide impregnation throwback (above) Since then Electro Arc discontinued machines like the F-5 in favor of the Metal disintegration line their reputation in the industry is long-lasting.  As the original maker of metal disintegrators, machines like the Electro Arc Model HK6VQT continue to offer the largest table model machine and heavy-duty superstructure available with heavy-duty power, and auto-feed for the fastest cutting disintegrator with increased machine operator productivity.  With innovation and efficiency, the line of metal disintegrators has grown to include over 40 models with an option to custom-build your machine and lots of accessory choices. Electro Arc Model HK 6VQT Metal Disintegrator This Electro Arc disintegrator will pierce any material that will conduct electricity and produce holes of any shape from .010 and larger.  The Electro Arc patented metal disintegrator design features maximum disintegrating power for the highest cutting speed.  No special skill is required to operate the metal disintegrators.  These built-to-last machines are still serving customers from over 50 years ago! See an Introduction to Electro Arc Portable Metal Disintegrators Below: