This project focused on designing a welding jig to accurately locate and weld the rear anti roll bar tabs and pillow block together as a subassembly before welding the assembly to the chassis. The goal was to control critical geometry early, reduce tolerance stack up, and ensure repeatable alignment during final installation.

I designed a dedicated welding jig to locate the ARB tabs and pillow block relative to the ARB axis. The jig referenced the ARB using a tangent V shaped feature to center the bar, while a through bolt and hose clamps constrained four degrees of freedom. Two snap on spacers constrained the remaining degrees of freedom, fully defining the assembly position.

Tabs and spacers preloaded the ARB against a custom reference plate, ensuring full constraint and consistent contact during welding. This approach allowed the critical geometry between the tabs and pillow block to be locked in before interacting with the chassis.

The jig components were designed for straightforward machining and assembly. Using the jig, the ARB tabs and steel pillow block were first welded together as a controlled subassembly. Once geometry was verified, the completed subassembly was welded to the chassis using the welding towers as references.

This two step welding process reduced tolerance stack up and improved alignment consistency between the ARB, pillow block, and chassis. The jig enabled repeatable subassemblies, simplified final chassis welding, and reduced rework during suspension installation.