we make these bitches at work by the boatload (woring on a batch of 75 now) we just redesigned this using the cast bellmount instead of a cut and weld at the top.



all strapped into the fixture


ready for tacking




16ga 304l to 14ga 304l
settings:
80amps (never hit full pedal)
16cfh
3/32"red tung
3/32" filler
brake clean before weld





16 ga 304l to cast stainless 1/4 thick
settings
120amps
16cfh
0.8pps
60% peak time (should have gone a bit lower)
5amps background
3/32 filler
3/32 red tung



all made possible by a miller dynasty 200dx

 

Well, well, well. Look at you bringing the bling. Nice work. I love the machined saddles that you use in the fixtures. Did you CNC machine those or where they purchased. I need to jig up a turbo mustang kit soon.

Thanks
David

 

machined out of 6061 its expensive way more accurate

they are doweled and screwed onto the posts(look at the post by the 90* bend). they work ay better than channels like we used to use. makes the fixture less bulky. when we first bend the pipe the parts for the flex and cat are the length we need to cut as well as on the first 90. once we mark and cut we put the flex and cat holders on as well as the post for the bellmouth flange.

this fixture was designed to be used for robotic cutting (14" chop saw mounted on a 6 axis arm). and once we get the arm programmed the cuts will be consistant enough for teh robots to weld them

 

oooo very very nice.. how much do you guys sell them for? or is this like a mass produced type deal for a company?

 

for our own product we usually make 50 or more in one shot. all made inhouse (except steel flanges and castings)

for private label we dont have a quantity limit persay, its based mainly on contract value

 

you're using robots to cut and weld this stuff, but you can't spring for some pneumatic clamps to replace those worm gears? you could save yourself a lot of time loading and unloading parts, and when you are doing 50 part runs, that can add up quick.

 

untill we find a saw with a smaller motor/body we dont have much room to work with.


we arent welding or cutting them robotically just yet, we are gradually moving that direction, this is kind of our test bench on how to fixture/setup parts for all of our products to be done that way. right now we only have a few peices cut (plasma and chop saw) on robots in a general use fuxture. like cutting single bends that some products require. we bought a used weld cell (2 motoman MIG 6-axis arms in one cell) and 2 450amp miller power supplies, we have programming of the arms in the bag but interfacing the miller machines to the computer that used to control hobart machines is taking sometime (nice to have an EE w/ a masters in the shop). we only have 2 people in the shop doing weld/fab work and we can kickout 50 exhausts from straight pipe to complete in about 4 days, not slow by any means. the robots will only slightly speed up the process, but consistancy and quality will be greatly enhanced, and allow us to broaden our product line (which we desperatly need) with our "free time"

 

looks sex. Just out of curiousity, are the mazdaspeeds actually quick at all? Or are they just heavy little pigs with some extra midrange torque?

 

pretty damn quick, according to wikipedia:
still front-wheel gayness... probably the best new front wheel gayness you can buy though.

 

Yeah 150mph out of the factory. The last fwd afaik to do that was the Daytona.. so it's pretty cool.