Lesson 6: Advanced Fabrication—Chassis & Frame
Duration of Days: 5
Lesson Objective
SWBAT:
Execute a structural weld that meets Electrathon safety standards for penetration.
Use a tube bender to create symmetrical frame rails without kinking.
How does "Triangulation" make a frame stronger without adding more weight?
What is the danger of "Heat Soak" when welding thin-walled tubing?
Triangulation, Gusset, Heat-affected Zone (HAZ), Penetration, Fish-mouth (Notching).
CT-CTE.MFG.E.30 (Perform welding)
CT-CTE.TRANS.D.14 (Structural integrity)
DOK Level: 4 (Extended Thinking)
Students apply welding and tube-bending skills to the vehicle's structural frame.
Misconception: "More weld beads make it stronger." Correction: Over-welding can weaken the surrounding metal.
Support: Use sub-assembly bins.
Extension: Create an "Exploded View" diagram of the assembly.
The Static Test: Fully assembled vehicle system test while on stands.