Every Ditch Witch machine is a sophisticated system of interdependent parts, the great majority of which are manufactured in our 30-acre plant in Perry, Oklahoma.

Although each part has its own, well, part to play, perhaps no parts are more important than those that make up a machine's hydraulic system. Because when the hydraulic system isn't working, neither are you.

A key component of a superior hydraulic system is a superior hydraulic cylinder, one that is created from the strongest steel, has the smoothest possible bore, and the most durable cylinder rod.

Jim Holba, a 32-year veteran of CMW, oversees the cylinder-manufacturing process from beginning to end. "From the quality of our raw materials to our equipment to our welding and cleaning processes, there is no detail that we don't give absolute attention," he says.

A recent tour of the cylinder cell began at the cylinder barrel skiving machine, where each cylinder barrel is bored to a roundness variance of less than .001″ and roller-burnished to a mirror finish. A near-perfectly round and smooth bore extends the life of both the cylinder and the piston seal, and ensures a precise fitting of the piston assembly.

Cylinder rods are created using a state-of-the-art friction welder that joins a forged rod end to an extremely hard (RC60), induction-hardened chrome cylinder rod. "Our friction welding process is the most reliable and cost-effective way to produce a 100-percent welded joint," says Holba. "The result is a very strong, low-profile joint that creates an incredibly durable cylinder rod."

Before the cylinder rod, cylinder head, and piston assembly are joined with the cylinder barrel, all parts are subjected to a thorough, two-stage cleaning process with cleaning and rust-preventive solutions. The department's cylinder parts washer is equipped with a five micron filtration system, which meets or exceeds the highest cleanliness standards in the industry.

"By eliminating contaminants at the manufacturing stage, and preventing contaminants from entering the hydraulic system during operation, our cylinders will help provide reliable hydraulic performance for a long time," says Holba.

Finally, before each new cylinder leaves the plant, it is tested, put under load, and cycled numerous times to simulate field conditions. "Everybody in our department has a personal stamp that he puts on the component he's responsible for," says Holba. "That stamp doesn't go on unless that person knows for sure that his work meets our standards. It's not just some arbitrary routine. It's a matter of pride."

Published in the Summer 2006 issue of The Underground.