tapping jigs

To develop jigs to help installers tap holes in I-beams at precise, repeatable locations.

Repeatability: Jig must enable consistent, repeatable hole placement across multiple I-beam installations.
Security: Jig must remain firmly secured during drilling and tapping to prevent movement or misalignment.
Drill guidance: Design should guide the operator to drill holes perpendicular to the I-beam surface.
Ease of installation: Jig should be quick and simple to install and remove, minimizing setup time for operators.

Design 1: Sheet metal bent to shape with a cross and hole stamped out. The crosses allow installer to create notches on the beam, and use a punch to mark create a pilot whole at the centerpoint.
Design 2: Two pieces of sheet metal, bent and stamped to form final shape. Parts are clamped together at the center with a fastener, along with drill bushings pressed into the holes.
Design 3: Sheet metal bent and stamped to shape, with drill bushings to help with perpendicular drilling. PEM inserts pressed into the bottom and side holes, to allow for fasteners to clamp the jig in place. Circular flange locating features help orient the jig to the desired location.

Each jig was fabricated and tested, eliminating location errors. Design 2 was easiest for installers to attach and remove.