This project was completed during my time as an engineering student working with the University of Arizona Baja SAE Team.

As a freshman, I was tasked with developing a cost-effective frame jig for the vehicle’s tubular chassis.

At the time, our team had all chromoly tubing CNC bent and notched off-site, but we lacked the typical fabrication resources used in motorsports—such as a dedicated welding table or CNC-cut steel jigs. This created a significant challenge: how to accurately locate and hold every tube in position for assembly without access to standard tooling.

In response, I designed a full-scale MDF lattice structure that acted as a one-time-use jig. The system precisely located each tube in three-dimensional space before tack welding, ensuring proper alignment and minimizing gaps between joints. To fabricate the jig, we leveraged a CNC router available through another department on campus, allowing us to produce the structure with high accuracy at a low cost.

Although the jig was not reusable, it provided a highly effective and affordable solution. It enabled the team to achieve tighter tolerances, stronger welds, and a more reliable frame without the need for expensive tooling.