What computer program do you use to design the chassis? Besides dimensions and angles, what other parameters can the program recreate?
I use Pro Engineer 3D modeling software. In designing a frame and suspension not only do I create dimension and angles on various parts but I can create stress and loads in given areas. Using this program I animate the suspension travel to iron out caster, camber, toe, and all my driveline angles.
What machine do you use in conjunction with the computer to cut out the sheets of steel?
I have a Torchmate Plasma CNC with a Thermal Dynamics plasma cutter.
What type of welding was used throughout the welding process?
For a lot of the frame and control arm honeycombing and non-visible internal welds, mig welding was used, but more often tig welding was used, as you can see here with the custom control arms.
What gauge steel was used to fab up and reinforce the control arms and crossmembers?
The control arms, just like the frame, are 1/8-inch plate and are also honeycombed throughout for added strength.
Do Dale and Ben do much of the welding in the shop based on your computer-generated design or do you handle both?
Ben and Dale do all the grinding…I am a primadonna…just kidding. Ben and Dale both are proficient in mig and tig welding and we all work on each component as a team. Quality is key!
How many hours, from start to finish were involved in designing and fabbing up the A-arms?
A pair of A-arms typically takes two full days, consisting of machining all the parts, creating a jig, and the actual assembly process. Designing a suspension system can take up to 12 hours.