3pt prototype done Options

[Qucifer]

Ok guys, here is the prototype of the 3 point strut brace. I will build a jig off of this one. The production bars will be made of the same 1" diameter tubing with a .095 wall thickness. They will be fully welded, gusseted, and powder coated.

[Qucifer]

Lubu, this is a prototype, basically a stencil to build a jig off of. It is only tack welded at this point. Every part that you higlighted on the picture is going to be supported by a gusset, so there will be no stretching or bending. I still have a few minor tweeks and stuff to do to the final design, but I am taking every precaution to make sure strength is not compromised. I orginally considered doing it the way you mention, if you look at the pics of my first prototype, the bar was cut at an angle, and welded to the flat plate. Doing it this way requires a very steep cut that is very hard to achieve.

Ill post a pic of what I am talking about.

You can see it almost looks like it is flat. Well, there is a cut on the bottom of the tube, allowing the bar to lay flat on the bracket. It does work, but the amount of time it takes to achieve those cuts makes it not feasible for me to make. The Jspeed design you posted has an angle machined onto the tower bracket that soaks up a lot of that tight angle. If you notice, the bar isnt even touching the bracket, just a thin angled gusset.

I assure you the finished peices will be very strong, and the price will be right. I do appreciate the constructive critisism though.