This is a welding jig I designed to convert a part called a "rigidizer" that is used to support the intersection of panels. They are cast aluminum 1/2" thick and we have to reconfigure some to make the "4 way" that we cannot get anymore till we find another casting company who can use our die. I designed this jig so I can weld singles, 3-ways, and 4-ways with the same fixture. The jig was originally designed and constructed from a new 4-way we had in stock at the time. That way, the welded pieces would have the identical dimensional configuration and would fit exactly like a new 4-way. I weld with GMAW, .035- 5356, at 120A @550ipm with 26cfh Argon and the casting preheated to 350-400 deg.. I switched from 4043 getting much better results and bond.

The photos in order show the fixture, 3-way set in place & toggled, add-on piece toggled into position, finish weld, and finish grind to dimension. I installed toggle clamp shields so as to keep splatter from building up on the clamps and spray the jig with WD-40 to keep clean. I hope someone can use this idea for a project or in the production of multiple quantities. This type of welding jig can be set up to weld 4 individual parts at the same time. Hope someone finds use for the design......Denny

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