TIG Welding
Senior year I took on the role of primary welder. I was not supposed to have this responsibility, but after a senior member left to focus on her academics I took on her role. I took on this work in addition to being the primary driver, having an above average course load, and being team lead. I was spread incredibly thin. I knew that the longer it took me to finish the frame the less time we would have to test the car, so I put any free time I had into welding. This led to more than a few all nighters, and over a three month period I put in more than 100 hours of TIG welding to finish the chassis and control arms before competition.
Control Arms
The suspension link above is made from 4130 chromoly tubing, with either .049’’ or .065’’ wall thickness. This material proved challenging, especially with the varied heat sinks my fixtures provided. I welded 12 of these 4130 lower links as well as 12 upper links made of 7005 aluminum. The links survived competition and I managed to drop some dimes along the way.
Roll Cage
The roll cage provided a set of challenges that the control arms did not. The 4130 tubing used here ranges from 1.25’’ OD with .090’’ wall thickness to 1’’ OD with .035’’ wall thickness. Welding these together required a delicate touch. Often I was out of position (had no good rest for my hands), upside down, and bent out of shape. This was less than ideal, but I made it work.