Tube End Welding Jig

Fabrication and assembly instructions for tie rod, UCA and pushrod tube end welds.

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BOM

Machining

Plate

Note:

• Plate thickness should be ~3/8” , it can be thicker, but should not be thinner (to accommodate counterbore)

• Material is whatever is available the easiest, aluminum or steel does not matter

• The distance between each pair of holes is the critical dimension, from longest to shortest length of hole pairs: 17.4”, 16.7” and 11.1” corresponds to the tie rod, push rod and UCA respectively.

• Surface machine the plate if there’s time to make the jig better toleranced.
  
  

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Assembly/Usage of Jig

The plate is designed to be used with the tie rod, push rod and UCA by moving the spacer and bolt to different hole pairings.

• Assemble the plate, spacer and nut like the figure below.

• The plate and rod end is sandwiched between the nut and bolt with the bolt entering from the counterbore side of the plate.

• Make sure the nut is snug on the rod end face.

• The rod assembly should be placed onto the jig fully assembled aside from the tube ends being welded.

• Once everything is assembled the tube end can be welded in place.

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