VERSATILE, ROBUST, MODULAR BUILDING BLOCK SYSTEM DO IT YOURSELF, OR ORDER COMPLETE FROM US COMPATIBLE WITH OTHER FRAMING SYSTEMS

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1 VERSATILE, ROBUST, MODULAR BUILDING BLOCK SYSTEM DO IT YOURSELF, OR ORDER COMPLETE FROM US COMPATIBLE WITH OTHER FRAMING SYSTEMS ASK US ABOUT OUR DESIGN AID SOFTWARE FIXTURES RACKS & CARTS TABLES WORKSTATIONS & jerry's.com Leaders In Framing Technology

2 Typical Applications Page 1

3 Modular Dovetail Building Components Articulating Arm Components Aluminum Enclosed Track Rail Components Tool Holders and Accessories Introduction to Modular Components Len & Jerry are two hard-working machine shop/design & build veterans, who knew that working smarter was essential to surviving in today s competitive market place. With extensive experience in machining technology, they have created a standard mechanical platform that will revolutionize the way that many machines and other metal products are designed and assembled. This low cost, robust, and flexible product line is a must for machine builders, manufacturing facilities, designers, and virtually anyone who wants an easy method to configure any metal product. Combine LEN & JERRY S components with steel or aluminum tubing and the possibilities are unlimited, and the cost is very modest. Compared to those expensive extrusion-based systems, LEN & JERRY S offers savings of 50% or more. Coupled with our Limited Lifetime Warranty, our components save dollars and make sense. Start saving time and money today on both Design and Build while delivering the highest quality product possible. LEN & JERRY S is where the smart money is. If you couldn t get through all the complicated sentences... Here Are The Cliff Notes Funny Name Serious Savings Low Cost, High Value Components Precision machined from 6061 aluminum alloy* Tensile 45,000 psi, Yield 40,000 psi, Shear 30,000 psi Reduces both Design and Build time and cost Creates higher perception of value Limited Lifetime Warranty protects your investment Easy to use and provides unparalleled flexibility Allows you to use standard steel and/or aluminum tubing Hey! It s an erector set for big people! * Some components are also available in steel. Call LEN & JERRY S at (586) for an engineering binder or product CD. Available in AutoCAD R14 and 2001 Page 2

4 Econo-Cart Len & Jerry s Transport Cart Base Frame Deck (Optional) Modular Components Towing Package (Optional) Low Rolling Resistance Wheels Basic transport cart base frame can be customized using any framing technology including Towing accessories available Complete custom transport cart available from Ideal for in-house assembly and customizing Available with or without deck Page 3

5 Front Tow Bar Swivel Wheel Bracket Same bracket with rounded bumper assembly. Rigid Wheel Bracket # Caster and frame bracket support for 1¹/₂ dia. tube cross rails and 1¹/₂ dia. tube vertical support. Page 4

6 1 & 1¹ ₂ Tube Size Caster Support Brackets Soon to be released for 1¹ ₄ tube size also. The hole pattern is for the two most common size casters, 1³ ₄ x 3 and 3 x 3. There are two sets of hole patterns for 1³ ₄ x 3, 90 to each other for fixed caster direction tracking. For off set loads near the edge of the cart, the casters can be moved outward to the end two holes. Caster wheel brackets need an additional two holes similar to Creform type products. These brackets can also be used to tie two vertical tubes together that support overhanging loads as shown on the front cover ¹ ₂ Dia. Tube Dia. Tube ¹ ₂ Caster Plate Assembly Caster to Suit Caster Plate Assembly Caster to Suit 1¹ ₂ Caster Support Bracket shown using 3 x 3 hole spacing. The square hole pattern allows tracking of the fixed wheel in either direction. 1 Caster Support Bracket shown using 1³ ₄ x 3 hole spacing. In this view fixed caster is tracking 90 to the two 1 dia. support tubes. Page 5

7 Caster Applications Casters can be mounted outside the cart frame when you have overhanging loads. Use extra length tubing for this extension. Tubes need to be a heavy enough wall thickness or solid bar stock to support the load plus shock load. This example is the engine carrier, shown on the front cover. The tow hooks are forged lift rings that are a standard product of. The cart tubing is 1¹ ₂ dia. x ¹ ₈ wall steel. Casters are normally mounted in the center of the bracket, but can be mounted outward to increase stability of the cart. Page 6

8 Has a 3 T-Slot section - We have a whole series of products that bolt directly to this t-slot extrusion or other manufacturers t-slot sections. Hole Size For ³ ₈ 18 N.P.T. 3 1¹ ₂ ³ ₄ ³ ₄ Nut Pocket For 8mm Square Steel Nut Surface A Saw Cut Hand Drill ¹¹ ₃₂ Hole For Bolts Fits 1¹ ₄ Tube or Solid Start Groove For Drill Point Available in 24 ft. length Extrusion Part # Can be cut to order Fabrication Process - Cut extrusion to length. Approximately 2 on each side. Saw cut on bottom side until blade hits surface A, hand drill two ¹¹ ₃₂ holes on each end about 1 apart. Use start groove to locate holes. Add bolts, washers and nuts. Page 7

9 Modular Dovetail Building Components Articulating Arm Components Aluminum Enclosed Track Rail Components Tool Holders and Accessoriesa Why Use Components? Machined from Extruded Material versus Cast to Shape clamps are machined from 6061-T6 extruded aluminum. Working the metal, by extruding will dramatically increase its strength. Such alloys like 6061-T6 are further strengthened by heat treatment. The advantage of extruded aluminum over cast aluminum is the elongation of the grain structure, which increases the hardness, tensile strength, and the amount it will elongate before breaking. Cast products have no grain direction and exhibit a random grain pattern that varies in size with usually some porosity. They have very low elongation, about 3%, which makes them brittle with little or no warning of failure. Products made from 6061-T6 extruded aluminum can be designed around a minimum elongation of 10.0% T6 extruded aluminum usually exhibits typical properties of 17% elongation compared to 3.5% elongation for cast materials. The typical tensile strength for extruded aluminum is about 25% greater than of a cast product. In clamp designs, we take advantage of the high elongation achieved from extruded aluminum. We use hole sizes typically 1/64 larger than the tube to be clamped, which allows us to clamp on standard mill tolerance, out of round tubing/bar stock-steel or aluminum. The wall thickness on the clamp that wraps around the tube is thinned down so that it will take the shape of the tube OD. When the clamp fits the shape of the tube OD, the additional surface contact adds rigidity for stiffness and non-rotation. Cast clamps have a precision sized hole about.002 larger than the OD of the tube. The clamps are not very elastic, but will close on a tube that is a few thousandths smaller. Each one of clamps has a starter hole to add roll pins for positive locking if required. Standard mill tubing is readily available at most suppliers that sell metal bar stock, and is about 1/3 the cost of precision sized tube, which is much more difficult to find. This allows you to buy tubing locally in your area, to save you money! Uses For Clamps And Components: End effector system for press rooms and body shops Racks Carts Fixtures Tables Assembly Work Stations Machines Conveyors Hand Apply Tooling This system will adapt to a variety of quick change tooling adapter systems Product CDs are available in AutoCADR14, SolidWorks 2000 at customer request. Minimum Mechanical Property Limits (Used for design calculations) 6061-T6 Alloy 356-T6 356-T6 Wrought Alloy Sand Casting Permanent Mold Ultimate Tensile Strength 38,000 PSI 30,000 PSI 33,000 PSI Yield Tensile Strength 35,000 PSI 20,000 PSI 22,000 PSI Elongation 10% 3% 3% Typical Mechanical Property Limits (NOT Used for design calculations) Ultimate Tensile Strength 45,000 PSI 33,000 PSI 38,000 PSI Yield Tensile Strength 40,000 PSI 24,000 PSI 27,000 PSI Elongation 17% 3.5% 5% Data is taken from published Aluminum Association data, ALCOA Structural Handbook, & ALCOA Aluminum Handbook. Page 8

10 Tow & Push Cart # (2) # (3) # (4) 1¹ ₂ Steel Tube ¹ ₈ Wall 1¹ ₄ 2mm Wall Plastic Coated Steel Tube (3) # (8) # Modified (1) # (1) # (3) 1¹ ₄ Steel Tube ¹ ₈ Wall (5) 1¹ ₂ to 1¹ ₄ Sleeve (4) 1¹ ₂ Steel Tube ¹ ₈ Wall (6) 8 Dia. Rigid Caster (2) # (4) # (8) # (4) 8 Dia. Swivel Caster (2) NOTE: (Ø) = Quantity Page 9

11 Len & Jerry s Modular Components Introduction To Dovetail & Accessories 30 Day Free Trial for Qualified Customers / OEM s No Risk Evaluation With Our Rolling Display Table Special Discount On Any Components Utilized or Purchased From The Sample Inventory All items shown are in extensive inventory All components are displayed for ease of viewing Maple top for stable work surface Entire display is on casters with brakes for easy movement Sample inventory in convenient bins Benefits of Modular Components Save up to 50% of both design and build cost over conventional methods. Offers unmatched versatility and adjustability. Simple allen wrench is only tool required. All parts are extruded 6061-T6 aluminum and CNC machined for ease of assembly and interchangeability. Compatible to build off 80/20 or equivalent extrusion systems Hughes Drive Sterling Heights, MI Phone: Fax: w w w.l e n a n d j e r r y s.c o m Page 10

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