Beverage Holder..... Jig Design for Production...

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Hey guys,Here's another installment of "how to" for those youngsters/newbies getting into the fabrication arena & needing techniques for producing multiple items with "repetitive consistency". The fellows who work in fab/production shops will attest to the fact that jigging will definitely improve consistency & profit margin that is the primary concern to stay in business.I had a customer call last week & wanted a steel beverage holder fabricated with his specs & not the size of the ones on the market(Chinese) with flimsy spot welds. He wanted the bottle/can height to be at 36" & wanted a steel scorecard plate(4"W X 12"H) attached to one of each pair. These holders are for himself & family members who go to a club that features horseshoe pits, bocci lanes, & cornhole pits. He asked me to see if I could make them at a reasonable price & it may be a good item to sell if cost could be kept to a price that would be attractive. I priced all the material at my metal supplier & just happened to have a couple pieces of 4"D pipe 5-6' long from my late company that was going to go to the scrap guy. I decided to cut the pipe in 3/8" slices to make the rings that would eliminate the ring-forming operation......really saved time. I decided to do a cut operation to start to determine if I could produce a quantity in a reasonable span of time. I cut the 3/8" HR rod (6) at a time on the drycut saw, the 1"W X 8"L X 1/8" HR flat stock (10) at a time, & drilled the 3/8" C/L hole (10) at a time. Here's the parts list:1) 3/8" HR rod 52"L..... one end bent to handle configuration & bottom semi-pointed.2) 3/8" rod 6"L w/semi point...... bent at mid-point(3") for base anchor fork.3) 1"W X 8"L X 1/8"T HR flat for can/bottle base drilled C/L w/3/8" hole.4) 4"D 3/8"W rings cut from pipe & 1/2" piece removed to get finish ID dia. of 3 1/2".5) 3"L X 1.5"W HR flat stock for scorecard clip-on plate. Later discussion to modify one of the holders to add a 4"W X 12"L X 16ga plate to be the scorecard plate & customer would add the numbers per his needs.I needed to make the jig to have all parts in location to weld in one operation. Some cutoff residual 1.5" sq tubing under the workbench would make the jig frame. Marking the rod for ring/can support location, the base was assembled & small angle pieces added to hold the rod in a fixed in position. I had to cut 3/8"W slots in the base ring supports to get C/L on the rings & locate the cut to the rod to be welded. I assembled all the pieces & could weld completely in less than (2) minutes.....worked quite nicely. I could cut, assemble, weld, prime & paint for these for a price of $65/pr & have a decent profit. The customer came over, liked them very much & pre-paid me for (6) sets for himself & family members. He indicated that other members of his club would probably want them & I would easily get another order for 20-30 sets. He took (20) of my cards to pass out to the other members.Ok....here's the pics..... there are (10), so please give me a couple xtra minutes to get them all on(2 posts). I hope this will provide some information to those who are inexperienced with production & help them understand how to make multiple pieces & have a good profit margin. Jigging definitely works..... try it....you'll like it. Feel free to ask any ?????.Denny Attached ImagesComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Here's the 2nd group..... Attached ImagesComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:HI Nice work I'm sure you will sell a bunch.As always some guy wants to suggest a change!!Why not put a small section of 1" X 1/8" flat stock about 6" up from the bottom for a foot pad.  This would give a way to push it in the ground with out it bending when pushing from the top???Still nice work.have funTom
Reply:Nice work as usuall Denny..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:God I love making jigs!!!! just something about getting it just right and making it so it works super smooth and efficient is just the best! Nice job!!!! I was thinking the same thing re; the foot bar except I'd go with round bar for stability instead of flat. ....... opps wait......"2) 3/8" rod 6"L w/semi point...... bent at mid-point(3") for base anchor fork."........just saw this. Great minds think alikeFrom one jig junkie to another, a chop saw table is your best friend when it come to faster production. 1/8" sheet deck with a back rail of angle iron to run a stop on. Glue down measuring tape so no more of the old in and out with the measuring tape. 8' decks on either side of the saw works great. I only mention it due your pic of your chop saw on a cart rig.PS..... Cornhole pits????? Should I ask????200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.
Reply:Hey guys,Thanks & I hope some of the newbies in the fab arena can use ideas like this to help them with their application.Yeah....... "Cornholing" threw me a bit too till it was explained. Don't know why that term was used other than the original game used corncobs. Here's a link to illuminate:http://www.cornhole-game.org/The customer indicated at his club, they use pits identical to a horseshoe pit & substitute the bag boxes for the steel h/s pins.To Tom(acourtjester):  The base fork pieces are lying on the weld table to the right of the needlenose pliers on pic 9. There are (2) for the 1st pair I was making. They push the holder into the grass easily & maintain a solid support quite nicely. Bert picked it up in his response.To Bert:  Yeah, I know you also like to jig. Really makes a difference for multiple runs. Yup, can work effectively with wood also. Here's a pic of the bottom forks.Denny Attached ImagesComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Originally Posted by yorkiepapTo Bert:  ....... Yup, can work effectively with wood also. Denny
Reply:My beer doesn't last long enough to be in a holder"Any day above ground is a good day"http://www.farmersamm.com/