Editing User:Eric/sandbox/Frame Head Assembly Jig

[[Category:Workshop Equipment for Local Manufacture]]
[[File:Vw670-1.png|thumb|alt=Cover page for VW 670 Frame Head Assembly Jig|Cover page for VW 670 Frame Head Assembly Jig]]
[[File:Vw670-2.png|thumb|alt=Instruction page for VW 670 Frame Head Assembly Jig|Instruction page for VW 670 Frame Head Assembly Jig]]
[[File:Vw670-3.png|thumb|alt=Blueprint for tool VW 670 Frame Head Assembly Jig|VW 670 Frame Head Assembly Jig]]

The jig is designed to hold a new frame head in such a manner that the welder has unrestricted access. It also ensures that the correct angle of the front axle cradle is maintained.

=== Construction Details for VW 670 ===

# Cut angles, T-sections and strip to dimensions given in list of parts. Have a new frame and new frant axle assembly ready for the purpose of fitting the jig.
# Drill 13 mm (?/? in.) holes in angle (1) as shown in drawing and step the flanges. 
# Cut and bevel the web of T-section beam (3) as shown in drawing, radius corners and bend to shape. 
# Drill a 9.6 mm (0.378 in.) hole in each of plates (4) and tap M 12. Cut plates to shape and weld to beam (3). 
# Drill a 9 mm (?/? in.) hole in plate (2) as shown in drawing, file to a slot 15 mm (1 in.) long, bend plate and weld to beam (3).
# Cut plates (6) to shape and weld to bear (3). 
# Re-cut threads of M 12 × 60 machine screws (5) right up to head and run screws into tapped holes in plates (4). 
# Attach front axle assembly and angle (1) to frame head by means of original hex. head balks. At the same lime make sure that any mis-alignment between the front axle assembly and the rear frame cross-tubes does not exceed the maximum permissible value of 15'. Then place beam (3) accurately on center line of frame tunnel and on center of angle (1). If necessary, true up plates (6) until they and plate (2) bear over their full width on the frame tunnel and beam (3) contacts angle (1) at two points as indicated in the drawing.
# Fix beam (3) in position by inserting a M 8 x 25 DIN 931 hex. bead screw in the foremost tapped hole provided for attaching the gearshift ball housing to the frame tunnel. Arc weld at points of contoct between angle (1), beam (3) and closer (1). 
# Unbolt jig and front axle assembly from frame and finish welding up angle (1), beam (3) and closer (7).
# Paint jig in prevailing colour of equipment and machines in the shop.
# Apply grease lightly to bolts and nuts.

Note:
All welds must be carried out by the arc welding process.