Control Arm Manufacturing Plans

Phase 1 - Manufacturing Inserts, Slotted Plugs, Apexes, lower plate, and cutting steel tubes to size.

Phase 2 - Manufacture jig parts, weld inserts

Phase 3- Put everything in the Jig and weld

Phase 1 (Late November-December)

Parts: Inserts, Upper Apexes, Lower Apexes, CA arm tubes

Manufacturing Order

Inserts: Start with cylindrical steel stock. The first step will involve getting the outside profile using the lathe. Then, you can use the lathe to thread cut and thread a hole in the insert for the rod end.
Steel tubes: Cut to proper length, cut slots in tubes
Upper Apexes: Waterjet outer profile

Phase 2 (December)

Parts: Jig Plates, Jig Spacers

Jig Plates: Waterjet
Jig Spacers: Lathe
Weld inserts to tubes

Welding inserts to tubes requires that the inserts are held flush with the tubes. I do not think this requires an actual welding Jig, however it will be important that we find a way to keep the insert flush welding.

Phase 3 (January)

Install jig components on optical table, install control arm parts in the jig, weld.

Parts

Part	Amount	Manufacturing Process

Part	Amount	Manufacturing Process
Upper Apexes	3	Water jet apex profile Machine housing and groove
Lower Apexes	2	Outsourced
Upper Tubes	8	Cut tubes to just above proper length using saw Precisely cut to length using mill
Lower Tubes	8	Cut tubes to just above proper length using saw Precisely cut to length using mill
Upper Inserts	8	Face Outer Surface, and remove material to outer diameter of larger cylindrical profile. Turn to a shoulder with the smaller cylindrical profile. Drill and tap hole, debur
Lower Inserts	8	Face Outer Surface, and remove material to outer diameter of larger cylindrical profile. Turn to a shoulder with the smaller cylindrical profile. Drill and tap hole, debur

Hardware:

Hardware	Amount	Name

Hardware	Amount	Name
Rod Ends	16	CMR4T - Q1A - 1/4''
Bearings	8	YPB4T - Q1A - 1/4''
Retaining Rings	16	HO-75 - Rotor Clip - 3/4''
Nuts	32

Welding Jig:

Parts/Hardware	Amount	Manufacturing

Parts/Hardware	Amount	Manufacturing
Front Alignment Plate Upper	2	Waterjet
Back Alignment Plate Upper	2	Waterjet
Front Alignment Plate Lower	2	Waterjet
Back Alignment Plate Upper	2	Waterjet	Mill
Spacers Upper	4	Lathe Remove material to get the outer cylindrical diameter Drill hole Part
Spacers Lower	4	Lathe Remove material to get the outer cylindrical diameter Drill hole Part
Bolts	6
Nuts	20