From Traditional Jig Building to Precision Chassis Fabrication

How Black Magic Race Cars moved from manual jig building to a precision fixturing system for faster, more accurate chassis fabrication.

CUSTOMER

• Black Magic Race Cars (Geoff) – Perth, Western Australia
• A specialist fabrication workshop focused on race car and high-performance vehicle fabrication, including chassis work, roll cages, and structural modifications for both street and drag racing applications.  
• The business is known within the performance and drag racing scene for custom chassis upgrades, suspension work, and precision fabrication on high-horsepower vehicles, including builds prepared for competitive motorsport environments.  
• Operating in a niche, high-tolerance space, Black Magic Race Cars delivers fabrication work where structural accuracy, repeatability and safety compliance are critical to vehicle performance and race readiness.  
• The workshop handles specialised tasks such as roll cage fabrication, bar work, chassis modifications, and performance upgrades, supporting both custom builds and race-prepared vehicles.  

THE CHALLENGE

Black Magic Cars had traditionally relied on in-house jig building using manual methods. While effective for years, this approach became limiting as fabrication demands increased.

As chassis builds became more complex and tolerances tightened, maintaining consistent alignment and squareness became more difficult.

Key issues included:

• Time spent building and adjusting custom jigs
• Manual measuring slowing setup
• Increasing demand for higher precision fabrication

Accuracy was no longer a preference, it was a requirement for race-level work.

THE CONSTRAINT

The existing system had not failed, but it had reached its limit.

The workshop needed to match the precision of modern fabrication methods, including laser-based processes. The shift was driven by a need to raise standards, not fix a breakdown.

Workshop conditions also influenced the need for a durable table surface, leading to the selection of a nitrided finish.

THE SOLUTION

The KO Welding team recommended options to suit his needs. After reviewing, Geoff selected his modular welding table system suited to precision chassis fabrication.

Configuration:

• K28 2000 x 1000mm KO Welding Table
• 2 x K28 800mm Super Square extensions
• K28 Versatile Kit + extra Accessories
• Nitrided finish for durability in local conditions

Approximate investment: $14,000 for the complete setup.

Key decision factors:

• Accurate grid alignment for chassis work
• Repeatable jig positioning
• Compatibility with laser-precision fabrication
• Long-term durability

This shifted the workshop from manual jig building to a structured, grid-based system.

INSTALLATION AND SETUP

Delivery and setup were straightforward:

• Freight arrived without issue
• Legs fitted and table assembled quickly
• Operational with minimal downtime

The system was integrated into the workflow without interrupting ongoing fabrication work.

THE RESULT

The impact was immediate:

• Improved setup accuracy
• Reduced time spent building custom jigs
• Better repeatability across chassis builds
• Increased confidence in alignment prior to welding

The workshop now operates with a higher level of precision aligned with modern fabrication standards.

The system supports both MIG and TIG welding, primarily on chrome moly tube ranging from 0.5 mm to 2 mm thickness.

CUSTOMER FEEDBACK

“I used to build my own jigs. It worked, but I realised accuracy was needed.”

“We now use laser precision. The table matches the standard of the work.”

“The product is very good. Service backed it up. Highly recommended.”

– Geoff

Black Magic Cars, Western Australia

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