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Jigging we just tried

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superdupercolin View Drop Down
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    Posted: Mar/29/2015 at 1:13am
Anyone else try this? It works really well but took forever to setup.

 
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Nate View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Nate Quote  Post ReplyReply Direct Link To This Post Posted: Mar/29/2015 at 2:17pm
On an extreme scale, yes. We also do our A-arms via a similar setup. Intersecting 2D laser-cut sheet metal seems to be a breeze to assemble so it doesn't take so long.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote superdupercolin Quote  Post ReplyReply Direct Link To This Post Posted: Mar/29/2015 at 3:00pm
Do you have any more pictures of the jigging you used? That looks pretty wicked
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Nate Quote  Post ReplyReply Direct Link To This Post Posted: Mar/29/2015 at 3:20pm
http://www.facebook.com/IowaStateBaja there might be some more on there... and give us a "like" while you're at it.


Here was the model.



Basically we made a 4x8 flat aluminum jigging table. Then we used sheet metal to locate critical points (first the roll hoop so it was square. Then things like the FBMs and Lower frame rails. To give it rigidity and keep all 2D parts, we intersected everything 90 degrees when we could. I used a lot of "intersection curves" to determine the correct dimensions. We also lightened things up when possible. The laser takes no time to cut these out.

Here's a condensed drawing for some of the parts.
uploads/2424/Sheet_Metal_Jig_Parts.PDF
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ankitk Quote  Post ReplyReply Direct Link To This Post Posted: Apr/19/2015 at 4:08pm
Would teams be kind enough to upload a few images of the fixtures they have used? Last time our team used wooden fixtures. While the 2D fixtures were accurate, cheap and quite helpful, the 3D ones were a PITA and pretty inaccurate. A few photographs and an explanation (if needed) would help us get some ideas and do things right this time
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Rollie Quote  Post ReplyReply Direct Link To This Post Posted: Apr/20/2015 at 8:33am
We have quite a few pictures on our facebook page:
 https://www.facebook.com/pages/Kettering-University-Baja-SAE/441336775898625?ref=hl

We used a 0.25" 4x8' sheet with water-jet holes and then tapped them for our multiple fixtures. The main constraints were d-shaped shaft collars that were mounted to the plate. All of our tubes are laser-cut so assembly is crazy simple. 3 day frame!



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Post Options Post Options   Thanks (0) Thanks(0)   Quote jarmumd Quote  Post ReplyReply Direct Link To This Post Posted: Apr/20/2015 at 1:21pm
It's an investment, but we (Auburn) has been using optical tables for a decade now.  These have hundreds of 1/4 threaded holes spaced an inch apart.




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Post Options Post Options   Thanks (0) Thanks(0)   Quote ankitk Quote  Post ReplyReply Direct Link To This Post Posted: Apr/23/2015 at 10:33am
Thank you for the highly helpful images. I don't we would be able to afford an optical table at the moment. Rollie's idea of waterjetting holes is a nice alternative to an optical table. We mainly had issues in the SIM members. Sim was bend at one end (rrh end) and was made in two parts. One from the FBM. Pictures attached below. 

http://tinypic.com/r/6syp6s/8

http://tinypic.com/r/2hftnv9/8
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Rollie Quote  Post ReplyReply Direct Link To This Post Posted: Apr/23/2015 at 10:35am
If you look at my second to last picture you could use a similar setup with the square tube and shaft collars to hold those tubes where you want them. 
Zac Watts
2013-2015 Kettering University
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ankitk Quote  Post ReplyReply Direct Link To This Post Posted: Apr/23/2015 at 10:59am
Some images of the fixtures we used last year. Tubes coped manually, frame welded manually. Entire car assembled in 10 days. Our material arrived super late last year(late by over 3 months)

http://tinypic.com/r/209rgqe/8

http://tinypic.com/r/vq1edh/8

http://tinypic.com/r/2w6yro3/8

http://tinypic.com/r/2r41jis/8

http://tinypic.com/r/jrtmw2/8




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Post Options Post Options   Thanks (0) Thanks(0)   Quote nikhilb Quote  Post ReplyReply Direct Link To This Post Posted: Aug/15/2019 at 12:37am
looking at your design it seems to me that the sheets used may flex. How did you controlled that and what was the thickness of the sheets used?

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