Help - Fence Spear Jig?

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Novice here:  I am making a 6' fence for my home. Does anyone have a picture of a jig/fixture they can share or any suggestions on how to weld the spear on straight?  I've done 25 and they are fair but each one has just a slight difference in position. Most people wouldn't notice but I will....I have about 225 more to go so before I do anymore I'd like make a tool that I can use to ensure they are straight.  Any suggestions?  Thanks in advance. Attached Images
Reply:A length of heavy angle (3/8" wall) at least 2 feet long and wider than the widest dimension of your spear in the box section where you will weld the spear head to the long box tubing.  Shim up the angle iron by tacking pieces of cut plate or flat stock until you have a level plane in 2 directions that match the dimensions of the box on the spear head and the box tubing that comprises the spear shaft .  Shimming or spacing is necessary to get away from the inside radius of the angle iron and to match the different apparent widths of the spear head box and the box tubing of the spear shank (haft).  Once you have made your jig you just clamp the head and a haft together on the jig and weld away.
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Reply:Thanks for the help. I think I'm following you. Am I doing it right?Last edited by tndude; 10-29-2013 at 11:42 PM.Reason: upload pic
Reply:It looks good to me.  Are you getting the consistency of fit that you need/want?  I don't see you having any issues with your jig.  Weld away and grin!
Reply:Thanks Walkerweld.  Its not bad.  The problem is that each spear is a tad bit different and they are not perfectly square.  I'm talking about the base of the spear - both on the side of the square base on the and the bottom (where it butts up against the angle iron) is not smooth so I'm using the edge of angle iron and the side piece I welded to the angle iron as a square-guide.  I'm thinking that this is probably the norm and you will never make them perfect.  It certainly does help make it easier so you don't second guess yourself because my table is flat and the angle iron is square so you are right......weld away and grin ;-).Thanks again.
Reply:Use plastic ones next time.   Glues the cast ones on after fence built.  I just have never found the to be consistent enough to gauge of the finial.Last edited by tapwelder; 10-30-2013 at 08:15 PM.
Reply:I hate welding them on because it is always high rust area.
Reply:The jig setup looks fine on post # 4 . Are you tacking them first ? Top , bottom, then left side right side to hold in position before welding out ?
Reply:Yes, tack two sides while clamped.  flip, tack other sides then weld.  I weld one side, flip weld opposite back side, then the other sides.
Reply:How 'bout, after clamping/squaring finial, then remove the angle iron. keep shim under tubing.  Then start welding opposite sides. It will save about 900 touches/tacks.  There is no need to do 4 tacks or reclamp. Do 2, that will save 450 touches.even proceeding the way you are 2 tacks, remove, then weld out.  Removing angle allows 3 sides welded before touching for the flip.Last edited by tapwelder; 10-31-2013 at 09:11 AM.
Reply:Thanks. Good idea.