Reverse Engineering in Dubai: 5 Real Workshop Cases — Costs, Methods & Timelines

Dubai's industrial sector runs on machinery — and a lot of that machinery is old. Construction fleets, marine vessels, power generators, and industrial plant equipment often continue working decades after the manufacturer stops making parts. When a critical component fails with no OEM available, the choice is simple: scrap the machine or reverse engineer the part.

In our 23 years in Ras Al Khor, we've reproduced thousands of parts that "no longer exist." Here are five real cases with honest cost and timeline data.

Case 1: Marine Bilge Pump Impeller — Aluminium Bronze

The problem: A marine vessel came into drydock with a failed bilge pump. The manufacturer had been acquired in 2011, and no replacement impeller was catalogued anywhere. The vessel was due to sail in 14 days.

What we did:

• ✓Received the corroded original impeller
• ✓Measured all 12 blade profiles with a CMM (Coordinate Measuring Machine) to ±0.01mm
• ✓Identified material as aluminium bronze (CuAl10Fe3) via spark test and hardness
• ✓Created full 3D CAD model with corrected blade geometry (the original was worn on leading edges)
• ✓Cast new impeller in AB2 aluminium bronze, then finish-machined all bore, face, and keyway dimensions

Result: New impeller delivered day 9. Pump tested at full pressure. Cost: AED 4,800 vs quoted AED 31,000 for a "universal replacement" that didn't match the geometry.

Case 2: Industrial Generator Timing Gear — Hardened Steel

The problem: A 2MW standby generator serving a data centre had a cracked timing gear. The OEM had been manufacturing this generator model in the 1980s and no longer supported it. Replacement generator: AED 850,000. Downtime cost: AED 35,000/day.

What we did:

• ✓Measured gear module, pressure angle, tooth thickness and profile on the cracked original (still measurable on undamaged teeth)
• ✓Confirmed: Module 4, 20° pressure angle, 48 teeth, case-hardened to 58 HRC surface/42 HRC core
• ✓Hobbed the gear blank on our gear hobbing machine
• ✓Heat treated (case carburised) to match OEM hardness specification
• ✓Ground tooth flanks for final dimensional accuracy

Result: Delivered day 8. Generator back online. Cost: AED 12,400. Total downtime: 8 days at AED 35,000/day vs indefinite downtime waiting for a replacement generator.

Case 3: Hydraulic Cylinder Rod — Non-Standard Thread Form

The problem: A construction equipment company had a fleet of excavators with a non-standard hydraulic cylinder rod end. The thread form was neither metric nor UNC — it was a proprietary specification from a Japanese manufacturer no longer active in the UAE.

What we did:

• ✓Used a thread gauge and optical comparator to reverse-measure the pitch, major and minor diameters, and flank angle
• ✓Confirmed: Modified metric, 2.5mm pitch, 38° flank angle (standard is 60°)
• ✓Single-point thread cut on our CNC lathe, producing the profile exactly
• ✓Surface finished rods to Ra 0.4µm and hard chromed for corrosion resistance

Result: 10 identical rods in 5 days. Verified by fit-test in the original cylinder. Cost per rod: AED 680. OEM equivalent from international sources: AED 4,200 each with 12-week lead time.

Case 4: Cooling Fan Hub — Cast Iron

The problem: An industrial cooling tower fan hub had fractured at the bolt holes. The tower served a manufacturing plant. Shutdown cost: AED 8,000/hour in lost production.

What we did:

• ✓The fracture was clean — we could assemble the pieces and measure the original geometry
• ✓Hub bore, flange diameter, bolt hole PCD (pitch circle diameter), and blade mounting features all measured with conventional metrology
• ✓Cast a new hub in grade 250 grey cast iron
• ✓Machined all critical features to the original drawing we created

Result: Delivered in 6 days. Tower back online. Cost: AED 3,200. A modern equivalent hub with different geometry: AED 18,000 plus 6-week delivery.

Case 5: Propeller Shaft Stern Gland Housing — Bronze

The problem: A 45-year-old workboat needed a replacement stern gland (cutlass bearing housing). The original had corroded beyond repair, and no records existed. The boat's owner had three 2-week charter bookings at stake.

What we did:

• ✓Traced the original interior and exterior profiles with a 3D scanner borrowed from a partner
• ✓Identified material as naval brass (CuZn40Pb2)
• ✓Machined the new housing from a large naval brass bar on our lathe and milling machine
• ✓Bored the internal profile to accept a standard cutlass bearing

Result: Completed in 7 days. Boat made all three charter bookings. Cost: AED 5,600 vs AED 75,000 for a custom casting from Europe with 16-week lead time.

Our Reverse Engineering Process (Step by Step)

Step 1 — Receive your part Deliver to our workshop in Ras Al Khor, or WhatsApp +971 56 671 8356 to arrange collection.

Step 2 — Feasibility check (same day) Can we reproduce it? From what material? At what cost? We'll tell you within hours.

Step 3 — Precision measurement CMM, micrometers, optical comparator, thread gauges, surface profilometer. We document everything.

Step 4 — Material identification Spark test, hardness test, and if needed, chemical analysis.

Step 5 — CAD documentation We create a full 2D drawing (and 3D model if complex) — you get a copy.

Step 6 — First-article manufacture One part made, inspected, and compared against the original before batch production.

Step 7 — Inspection and delivery Full dimensional check. Delivery across Dubai and UAE.

What We Need From You

• ✓The original part (even damaged or heavily worn — we can work with remnant geometry)
• ✓Any documentation: part numbers, photos of the original installation, old catalogues
• ✓Operating conditions: temperature, pressure, speed, chemical exposure
• ✓Quantity required
• ✓Your deadline

Emergency? WhatsApp us a photo now at +971 56 671 8356. We can often give same-day feasibility on straightforward parts and start work the same evening for urgent cases.