AstroSafariAtlas · Field Manual
Common fabrication practiceSafety-critical§ fabrication

Tools, Welding Capability, and Safety Requirements

Honest 'what you need to have' list — including when to outsource rather than attempt.

Lifting & support

  • Rated jack stands, wheel chocks, level surface.
  • Frame stands positioned at load-bearing points, not at rocker sheet metal.
  • Second person for spotter duty during heavy lifts.

Measurement tools

  • Long tape (7.5 m+), plumb bob, string line, laser level.
  • Digital angle finder / inclinometer for driveline and caster.
  • Calipers for spline/pin measurements.
  • Torque wrenches (foot-pound and inch-pound, calibrated).

Welding & cutting capability

  • MIG welder capable of the material thickness at the intended duty cycle — not the minimum-spec home unit.
  • Cutoff wheels, grinder, plasma cutter (or torch) with fire watch.
  • Fire extinguisher rated for the environment, positioned within arm’s reach.

Stop-work · Fuel & brake lines during welding

Weld splatter and grinder sparks near fuel lines, fuel tank, or brake hoses are a fire and catastrophic-failure risk. Remove the fuel tank or provide a purpose-built barrier — do not rely on “being careful.” A fire watch stays for the full cool-down.

PPE

  • Auto-darkening welding helmet with fresh lens.
  • Leather gloves for welding, cut-resistant gloves for grinding.
  • Respirator when grinding coated steel or working around used gear oil.
  • Safety glasses under the helmet — always.

When to outsource

Structural welding on steering, suspension, and load-bearing frame is safety-critical. If you are not producing welds that would pass inspection, hire a qualified fabricator. There is no shame — there is only outcome. Alignment and driveshaft balancing are usually outsourced; engineering review is required before final welds.

What we know

  • • Structural welds on steering and suspension are life-safety welds.
  • • Hot work near fuel and brake lines is a documented fire-risk category.

Proposed design targets

  • • Program plans engineering review before final welds and outsource of alignment and driveshaft balancing.

Must be verified before fabrication

  • • Fabricator selection for the reference build — not yet decided.

Related SFA articles

§ chassis

Frame Reinforcement, Spring Hangers, and Load-Path Engineering

Load-path thinking, boxing/plating decisions, hanger alignment, weld strategy, corrosion protection, and inspection.

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§ steering

Crossover Steering Geometry for an Astro SFA Swap

Box, pitman arm, drag link, tie rod, Ackermann, bump steer, and why welded 'bend hacks' are not standard practice.

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§ fabrication

Complete SFA Conversion Build Sequence

Gated phases from requirements through trail validation. Each phase has prerequisites, stop-work rules, and a persistent checklist.

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