ATV Rack Extension

Construction: The construction of this project will take place over the time period of winter quarter. The bracket attachments will have to be cut and shaped to the drawing and drilled as well as cutting the square tubing to length first. The holes will then be drilled into the two pieces of tubing that will slide into the bed of the truck and attached to the other rack is drilled before the pieces will be welded on. The steel hollow beams, brackets, and gussets are welded together on campus by a few friends. The diamond plating will then need to be ordered to length and bent per engineering. The diamond plating will then be attached with nuts and bolts on campus to the steel frame. The holes will be match drilled onto the diamond plating from the brackets to ensure that the holes will concentric with each other. There will be four places total that the diamond plating will be bolted onto the steel frame. The ATV rack extension will then be able to be pinned to the existing rack. The two bars that will be welded to the steel frame will need to be drilled as well.

Description: This project will consist of the main assembly that will be welding the square hollow beams together so that they have a nice uniform look and stability. The diamond plating will be bolted to the beam assembly to ensure that there is no movement between the two. The beam assembly with the brackets will be the support to the diamond plating that will be holding and supporting the weight of the ATV.

Each part number with in this assembly will be numbered. A-001 is an example of how the beams will be numbered with in the sub assembly. Then the brackets and diamond plating will have their own number such as B-001 or C-001. Some of the parts within this final assembly have duplicate parts that are exactly the same. Above the title of that part will say how many of that part will be manufactured. The parts that with in the subassembly will be in the A group. The parts that are attached in the final assembly will be a part of the B group. The sub assembly and final assembly will be part numbered in the C group.

Manufacturing issues: Some of the manufacturing issues that may be of concern are listed below:

• Welding callouts need to be called out correctly on all drawings, because one beam may get welded to the wrong location or wrong part.

• Plasma Cutter and not exact holes.

• Hole match up with bracket and diamond plating

• The holes for the pins wrongly located on new rack or original rack.

Like it was stated above these manufacturing issues have been resolved during the manufacturing process. For example the plasma cutter was having issues with cutting the hole in the brackets, because of the female, and male cuts were either significantly larger or significantly smaller. Lots of time working with the machine the plasma cutter was able to make a direct cut and only be about 0.020 off of the hole which is okay because there will be a bolt going through that hole.

The hole match up with the bracket and diamond plating was fixed by match drilling to the diamond plating from the bracket to ensure hole location is correct.