|This is the Daihatsu Fourtrak Custom Shock Tower Cross Brace installed and in use with the new leaf sprung suspension. Photo Credit: Eric McGrew from an iphone 4.|
Tuesday, January 12, 2016
Simple Jig: It's So Simple I Almost Didn't Think Of It
On one the recent Daihatsu Fourtrak project components that I had to fabricate up, I found myself in a bit of a jamb. Nothing serious, but definitely something that occurs while fabrication from time to time.
I found that I needed to align a bracket with the upper surface of a cross brace. This particular cross brace had been notched on one end, and not on the other. Both sides where to have the same bracket attached with an equal drop offset. This drop offset had been determined using the upper surface of the cross brace before it was realized that any notching would be required.
To try and figure out the best option, I first thought about a number of possible solutions. All of them would have worked. Some of them would have required a bit more guestamation, while others a bit more jig design and setup.
I kept thinking, there’s definitely got to be a better way. A more simple way… So, after around 3 minutes, I realized there was a super simple, quick and easy jig that I could set up to get the top of the bracket even with the top of the cross brace, while keeping it firm enough to tack up, and then fully weld.
My solution, to use a piece of flat stock, a C-clamp and welder’s magnet.
I checked for anything that would impede the flat stock from laying flat.
I used the C-Clamp to tighten the flat stock to the upper surface of the cross brace that the bracket needed to be welded too.
Taking the Welder’s Magnet, I placed the magnet on the side of the very end of the cross brace. Allowing it to hold the bracket firmly to the edge, while allowing me to slide the brace both upwards, and side to side.
After having set up the jig, and placed the end bracket that was to be welded to the cross brace, I went back and checked my measurements just to be sure before any final welding was to be done.
Once everything checked out, I welded on the end brackets to the cross brace, and test fitted it inside the Fourtrak chassis.
There you have it. After a few moments of thought, a couple of very simple tools, and a scrap piece of flat stock, I was able to get an exact alignment, and get on with other work that needed to be done. Sometimes the best jigs, are the easiest jigs…