We used the tube coping and cutting system to make all the cuts for the tubes in the lower plane of the vehicle. This plane will support the battery modules and the seats.
From there, we set cleared the welding table and rolled out a sheet of grid paper. Using the drawings generated from the CAD model, we drew out the center lines of the tubes.
We cut around 40 wooden tube supports out of 2-by-4s to hold the tubes in place while layout and welding. These supports were secured onto the wooden table with their center lines aligned with the lines drawn on the table.
Finally, the cut tubes were placed into these supports. After a little positioning and perfecting of tube-ends, the plane was welded with a TIG machine using ER70S-2 filler.
This general process will be repeated for other planar sections in the frame, which will then be joined together to make a
PH-571 