Power Cube Jig

=Overview= The power cube jig was developed by Mike Hill of the Open Hardware Center during his DPV at Factor e Farm. It enables rapid alignment of Power Cube parts and is incredibly useful during bulk welding of multiple power cubes.

=Instructions=

Optional: Jig for frame assembly
The welding “jig” in the image below is helpful to insure square angles while assembling the Power Cube. Materials List ¼” x 2” x 2” Angle Iron: 14' ½" Rebar: 7' 2”

Cut List Type	Length	Dimensions	Quantity	Color
 * Angle	22"	¼” x 2 x 2"	2	(red)
 * Angle	26"	¼” x 2” x 2”	2	(yellow)
 * Angle	29"	¼” x 2" x 2	2	(green)
 * Rebar	30.5"	½"	1
 * Rebar	27"	½"	2

Jig Assembly (optional)


The jig is an optional piece of fabrication equipment that can be very useful to have should you be creating several power cubes concurrently. The materials for the cube are assembled in the jig in half sections and tacked and welded in place.

Materials List

Total Length 14'  Angle (2"x1/4") 7'2" Rebar (1/2")

Cut List



Assembly of the Jig is fairly straight forward. Tack and weld the pieces in place.



Be sure to note the overlapping order and the notch made at the bottom of the 1'10 1/4" piece (red). Torch holes in the corners below the frame as seen above. This allows room for the welding torch to get to the PowerCube while welding.



Also note that the corners are offset 3/4" (1/2" measured on the interior), to give room for the cube to sit snugly in the frame (and a convenient gap for welding the corners.)

Tack weld the two shorter rebar sections at roughly a 45 degree angle on the sides. Add a long rebar section to span the gap. Precision is not as important with these, they are more there for stability.

With any luck, you'll have your jig, ready to crank out Power Cubes with!

Jig Fully Assembled.