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Hello,

We're designing an electric vehicle made from bend tubing.
The goal is to make a kit which can be easily build by the buyer.

My question:
Do you know of solutions which can be a good alternative to welding, to connect the tubing of the frame.
Or maybe some helpful inserts, of some sort, to make the welding easier.
 

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Hello,

We're designing an electric vehicle made from bend tubing.
The goal is to make a kit which can be easily build by the buyer.

My question:
Do you know of solutions which can be a good alternative to welding, to connect the tubing of the frame.
Or maybe some helpful inserts, of some sort, to make the welding easier.
There are not many good alternatives to welding. You can search out bolt-in rollcages to see how that is typically done; to join tubes, you need to have sliding sections that have crossbolted joints.
If you're familiar with bicycles, you could do something like frame lugs, where the tubes are brazed in.
Making welding easier is most easily accomplished by not having any complex joints (where more than two tubes meet, or very acute angles) and by pre-mitering all the required joints. Include as many alignment points as possible so that the customer can check their work as they go; and make it possible to tack everything together to have cross-bracing before final welding is done, to minimize warpage of the chassis.
 

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