Production Techniques Made Easy....PartIV

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Hey guys,Here's another jig use for drilling multiple plates. Bear in mind that a jig can be designed & constructed specifically for the number of pieces you want to do at a time. These plate jigs I made were for 1/8" steel & aluminum plate & I used 1" angle, so that allowed me to drill (7) pieces at a time with the template also being 1/8". You can use 1.5" angle if you want to do more.....it's really up to you.You can see there are (2) sizes of plates I set up for as there were 1500 each needed with (3) different hole configuration templates. As you can see, each jig has a piece of angle in the front to load/unload the pieces & locked in place with a small toggle clamp to maintain a snug fit & eliminate any wobble.The 2nd series of pics are another type of jig to make an odd configuration the owner needed for an optional feature a customer wanted. These are a "mini-cantelever" that locked into the slotted rails we used to mount the shelves & cabinets to the cubicle panels. Yes, many types of odd shapes & configurations can be accomplished using a jig to assemble & weld together. These pieces were small & the jigs were small so the size of a jig can be quite small to damn-near room size. It's all up to you as to the level of piece size & number of items needing done.Ok, gonna need (2) posts to get all the pics on..... PLEASE WAIT TILL BOTH ARE ON. Thanks....Denny Attached ImagesLast edited by yorkiepap; 03-15-2011 at 02:49 PM.Complete 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:2nd Group:Don't hesitate to ask any ??? if you need to know a method that may help you.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:these are some great ideas... i should try this with my next 'fab' project.
Reply:The only thing I don't like about drilling thru a template is that after awhile the holes aren't true anymore due to the drill wearing them out of size. I'd go the same route but mark it lightly with a dab, take it out of the jig and drill it.Quite a few years back I was fabbing and installing plow fronts on our (NSDOT) tandems. As there were 15 or so to do I took the best part of a day making a template to mark the truck frame for drilling, transfer existing frame holes to the plow front and mark the frame for cutting. One of the guys was working in the other shop had nothing to do so they, management, figured he can mark and drill holes. I gave him the template I had made, nicely drilled with 3/32"< dia. or so holes, just big enough to go thru with an auto centerpunch. The idea was to mark the holes, remove the template and dab 'em heavier for drilling. When I went to get the template back the holes had all been drilled out to 21/32 dia. He figured it'd be faster if he saved a couple of steps so he clamped the template to the frame and drilled thru both. Ever try and line up a 21/32 dia drill bit in a 21/32 hole in a piece of 16ga, it don't work that well.....Mike
Reply:In most cases your top jig plate (template) would be thicker and have drill bushings installed as they are hard and can maintain accuracy. I guess it all depends on how many you parts you are dealing with.
Reply:Do you have any ideas for holding two pieces of 2" pipe for butt welding?
Reply:Hey jcaro,Here are some pics of a tube welding jig I made that can handle up to 1.5" dia.. You could just simply upsize it to handle 2"-3" dia. & use some 2" angle for the rest area with a welding opening as I have done. You gotta construct the entire jig before cutting the welding opening.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:Thanks for posting this design.  I should be able to size up and make what I need.