Prototype Three

The changes made to the third prototype refined the design and decreased assembly and installation time. The most visible change, the logo, was added to the cut file instead of needing to be welded on as a separate piece. 

I enlarged the holes to access to screw nuts, changing the geometry of the mounting tabs so that the edges aligned more precisely, elongating the rectangular notch holes for the side part tabs to fit with less filing, and creating weld tabs to increase weld accuracy.

The left photo is prototype two. In prototype three, the middle picture, I made the hole larger so that it may fit a 5/16” socket tool making installation easier. It certainly made room for a socket tool but also weakened the part significantly. The mounting tabs could be bent by hand, much too easily for any strength standards. It was evident at this point that a fourth prototype was imperative.

The left photo is prototype two. In prototype three, the right picture, I adjusted the geometry of the folding tabs. By changing the shape, they were able to align better.

Adding tolerance to the top and bottom of the rectangular holes, decreased assembly time. Previously, filing was needed to assemble the parts, but now, they fit together directly after being water jet cut.

While welding, it can be difficult to see where to start and stop. By giving this part tabs, welding could be more precise.