The TomyJack cases are manufactured by Synertek Industries. With Synertek’s help, we were able to develop an expertise in designing and manufacturing welded and riveted aluminum cases. It is very difficult and time consuming when welding exceptionally thin aluminum. This is why the majority of manufacturers opt for riveted joints. The reason for this is not because the rivets are nice-looking, but rather to save time and to save on welding costs. This is because it takes three minutes to rivet one case, and can take up to forty minutes to weld the same joint.
Therefore, the question is; why weld? The reason is simple; it enables the case to be solider and more durable. In order to achieve the optimum resistance to stress, a riveted joint must meet certain criteria. The rivet’s diameter mustn’t exceed three times the thickest sheet of metal’s thickness. Along with that, the space between each rivet needs to be between four and eight times the rivet’s diameter.
Now, if we apply this information to our motorcycle cases, the following would be true:
The sheet metal’s thickness is between 1.2 and 1.5 millimeters, therefore the rivet’s maximum diameter should be approximately 4.5mm, with a distance of 15 to 36mm between each rivet. If we were to respect this criterion when fabricating our cases, they would be as durable as if they were welded. But then again, never forget that most manufacturers are always trying to cut costs, which leads them to install two to three times less rivets than they are supposed to, which then causes them to be less sturdy. This is why welding the joints becomes a more appealing option since we do not want our cases to look like the hull of the Titanic.
This is why, in order to manufacture our cases, we start the process off with cutting the sheets of aluminum by using our laser cutter. We then bend the parts on our CNC press breaks with the greatest precision possible. Laser cutting and precision bending enables us to attain beautiful weld seams that cause minimal distortion to the welded parts. Afterwards, the welded products are painted with a powder coating that is then cured on site.
This entire process enables us to achieve a uniform and highly resistant painted finish. The last step is the assembly. We need to attach the various latch components with rivets, along with the hardware that is used in creating our TomyJack cases.