Jack Brubaker was the supreme "gadget man".  He had jigs and 
fixtures set up for producing everything from "S" hooks to 
lamps to iron lilies.  At his demonstration he passed out 
this list of guidelines and tips.  I hope you find it 
useful.

Bending Jigs and Welding Jigs

Jack Brubaker
Brubaker Designs
2900 Shepherd Road
Nashville, IN 47448
(812)988-7830

Procedure for Developing a Bending Jig.

1.  When possible, make several different prototypes.

A.  Refine design

B.  Visualize bending jig, adjust design if necessary to 
facilitate jig.

2.  Do you want to make the hard choices while sitting in a 
comfortable chair or while standing at your bench?

A.  Make a drawing if you like your comforts.  Think of it 
as a right brain 3D crossword puzzle.

B.  Sometimes it is easier to invent your way through the 
design while standing at the bench, but it can tie up a LOT 
of production time.

3.  Form bending fences in short sections against the 
prototype (hot bend with vise grips and tongs).

4.  Hot form bottom fence or cut from plate.

5.  How will the piece be pulled around the jig?

A.  Hand
B.  Forks
C.  Lever with roller or lever with forming fence.

6.  If lever operated, give very careful thought to the 
placement of the pivot point.

A.  How does changing the pivot point effect pulling the 
metal around the jig?
B.  How does it effect clearance around the jig?
C.  How can it improve the control of the metal at the end 
of the piece (often the hardest part to form) by varying 
direction of motion?
D.  Is the piece tapered? A tapered piece often needs a 
closer fit between the the fence and the pushing surface.

7.  How is the piece held in the jig at the beginning of the 
cycle?

A.  Against a pin?
B.  Neck that jams between two fences?
C.  Built in toggle clamps?

8.  Has the jig been designed so that a formed piece can be 
removed?  Can it be removed without distortion?

9.  Expect welding distortion to warp the jig.  Before 
adding extra bracing, correct for distortion.

10.  Run a few pieces to check how it works.

11.  Make any needed adjustments.

Developing Welding Jigs

1.  Identify what points can be used to position pieces 
(points must be on sections of parts that are going to be 
consistent from one part to another).  Usually three points 
per piece, one of them at each weld.

2.  Decide what position is best for ease of welding. 
(upside down, sideways etc.)

3.  What type of clamps will be used to hold the parts in 
position against the jig?  Gravity can often be used to 
position a part but will not resist distortion.

4.  Build jig around assembled prototype

5.  Try the jig and make adjustments.

************************************************************
Steve Hackbarth, proprietor of Badger Village Blacksmithing, 
sent in this handy little tool idea.  It is cut from a piece 
of angle iron approximately 10 inches long.  First find the 
center, saw cut through the web on one side only, then heat 
and bend back upon itself.  Insert a thin piece of cardboard 
(about a buisness card in thickness) into the gap and drill 
the holes.  The cardboard helps keep the drill centered.  
That's it!!