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What Are Larry Lugs?
In the world of heavy machinery, Larry Lugs refer to weld-on grouser bars or replacement pads that are used to rebuild worn track shoes on dozers, excavators, and loaders. These lugs are named colloquially—possibly after a brand or a particularly enterprising machinist—and are a cost-effective way to extend the life of undercarriage components without full replacement.
Track grousers—raised ribs on each shoe—are essential for traction, especially in soft or slippery terrain. Over time, they wear down from contact with rock, asphalt, and constant abrasion. Replacing entire track shoes is expensive and time-consuming. Instead, operators often weld replacement lugs onto the existing shoes, effectively recreating the traction profile.
Undercarriage Wear: An Expensive Reality
The undercarriage accounts for 50% or more of the total maintenance cost of tracked equipment. Track shoes, links, pins, bushings, and rollers all degrade through routine use, particularly in harsh environments like:
Welding Lugs: The Rebuilding Process
Rebuilding track shoes with Larry Lugs involves several important steps:
A small construction outfit in rural Montana faced a dilemma. Their 1970s Komatsu dozer had severely worn grousers and couldn’t climb the slopes needed for a reservoir project. A new set of track shoes would cost over $8,000—more than the value of the machine.
Instead, the owner purchased 120 Larry Lugs for under $1,000 and hired a local welder to install them over a weekend. The dozer’s traction improved dramatically, and they completed the job without delay. That same machine, years later, was still in operation on small grading jobs.
Terminology Note: Grouser vs. Lug
While "lug" and "grouser" are often used interchangeably, there is a technical distinction:
Advantages of Using Larry Lugs
Other options for restoring traction without replacing the full undercarriage include:
Weld-on lugs like Larry Lugs are part of a long tradition in the heavy equipment world: the field fix. In remote logging camps, mining sites, or hurricane cleanup zones, resourceful mechanics have always adapted tools and materials to keep machines running.
During the cleanup after Hurricane Katrina, many machines were refitted on-site with re-welded tracks to push debris from roads. In northern Alberta, welders keep a stock of grouser bar in their mobile rigs to make emergency repairs on timber skidders 100 miles from the nearest shop.
Conclusion
Larry Lugs exemplify practical ingenuity in heavy equipment maintenance. For owners of aging equipment or those working far from parts suppliers, weld-on grouser lugs offer a smart, affordable solution to traction loss. With proper prep and welding technique, they can restore undercarriage function for thousands of hours—extending the life of old iron and keeping crews productive. Whether you're a seasoned operator or a weekend land clearer, it's one of those old-school tricks that still gets the job done.
In the world of heavy machinery, Larry Lugs refer to weld-on grouser bars or replacement pads that are used to rebuild worn track shoes on dozers, excavators, and loaders. These lugs are named colloquially—possibly after a brand or a particularly enterprising machinist—and are a cost-effective way to extend the life of undercarriage components without full replacement.
Track grousers—raised ribs on each shoe—are essential for traction, especially in soft or slippery terrain. Over time, they wear down from contact with rock, asphalt, and constant abrasion. Replacing entire track shoes is expensive and time-consuming. Instead, operators often weld replacement lugs onto the existing shoes, effectively recreating the traction profile.
Undercarriage Wear: An Expensive Reality
The undercarriage accounts for 50% or more of the total maintenance cost of tracked equipment. Track shoes, links, pins, bushings, and rollers all degrade through routine use, particularly in harsh environments like:
- Quarry and demolition work
- Forestry
- Winter snow removal with tracks
- Road construction on abrasive surfaces
Welding Lugs: The Rebuilding Process
Rebuilding track shoes with Larry Lugs involves several important steps:
- Preparation: Clean the surface thoroughly. Use a grinder to remove rust, old weld, and oil. Preheat the shoes if working in cold conditions to prevent cracking.
- Fitment: Place the lug centered and aligned with the existing wear pattern. Use clamps or tack welds to position it before full welding.
- Welding: Use 7018 low hydrogen rods or flux-core wire with proper amperage. Weld on both sides of the lug to ensure secure attachment.
- Post-weld cooling: Avoid rapid cooling, which can cause brittleness. Let the shoes cool naturally, especially in winter.
- Taller grousers for deep mud
- Shorter, rounded profiles for hard rock
- Staggered or offset patterns for better snow clearing
A small construction outfit in rural Montana faced a dilemma. Their 1970s Komatsu dozer had severely worn grousers and couldn’t climb the slopes needed for a reservoir project. A new set of track shoes would cost over $8,000—more than the value of the machine.
Instead, the owner purchased 120 Larry Lugs for under $1,000 and hired a local welder to install them over a weekend. The dozer’s traction improved dramatically, and they completed the job without delay. That same machine, years later, was still in operation on small grading jobs.
Terminology Note: Grouser vs. Lug
While "lug" and "grouser" are often used interchangeably, there is a technical distinction:
- Grouser: The raised portion of a track shoe that contacts the ground, typically factory-machined.
- Lug: A general term that may refer to replacement grousers, tire traction features, or bolt-on pads.
Advantages of Using Larry Lugs
- Cost savings: A fraction of the price of new shoes
- Custom traction profiles: Tailor lug height and shape to suit terrain
- Reduced downtime: Quicker installation than full shoe swap
- Salvaging rare parts: Useful for older or obsolete machines with limited parts availability
- Heat warping: Excessive welding heat can warp the track shoes, affecting fit and ride
- Cracking: Poor welding technique or incompatible steel can lead to premature failure
- Uneven wear: If lugs are misaligned or inconsistently sized, they may cause vibration or abnormal track wear
Other options for restoring traction without replacing the full undercarriage include:
- Bolt-on ice cleats or traction bars: Useful for temporary applications in snow or ice
- Hard-facing rods: Build up worn areas with wear-resistant welding material
- Aftermarket shoes with replaceable grousers: Found on modern machines, though costlier
Weld-on lugs like Larry Lugs are part of a long tradition in the heavy equipment world: the field fix. In remote logging camps, mining sites, or hurricane cleanup zones, resourceful mechanics have always adapted tools and materials to keep machines running.
During the cleanup after Hurricane Katrina, many machines were refitted on-site with re-welded tracks to push debris from roads. In northern Alberta, welders keep a stock of grouser bar in their mobile rigs to make emergency repairs on timber skidders 100 miles from the nearest shop.
Conclusion
Larry Lugs exemplify practical ingenuity in heavy equipment maintenance. For owners of aging equipment or those working far from parts suppliers, weld-on grouser lugs offer a smart, affordable solution to traction loss. With proper prep and welding technique, they can restore undercarriage function for thousands of hours—extending the life of old iron and keeping crews productive. Whether you're a seasoned operator or a weekend land clearer, it's one of those old-school tricks that still gets the job done.
