When it comes to upgrading the suspension on a classic car or truck, quality matters. From improved handling to long-term durability, the parts you install play a major role in how your vehicle performs on the road. That’s why Classic Performance Products (CPP) focuses on designing and manufacturing many of its suspension components right here in the USA, using modern engineering tools and robotic welding technology.
In this behind-the-scenes look, we follow the process of how CPP tubular control arms are engineered, built, welded, and finished before they ever reach your project vehicle.
It All Starts With Engineering and 3D Modeling
Every great product begins with careful design and engineering. At CPP, the process starts in the engineering department, where original parts are digitally scanned and recreated in SolidWorks.
Using advanced CAD modeling software allows engineers to:
- Accurately reproduce factory geometry
- Improve strength and fitment
- Create precise manufacturing files for production
Once the digital model is completed, 3D-printed prototype parts are created. These prototypes help engineers verify dimensions and determine how the components will fit together during manufacturing. This stage ensures every suspension component meets the strict fit and performance standards expected from CPP products.
Precision Fixtures: The Key to Robotic Welding
Before robotic welding can begin, the manufacturing team must first create precision fixtures. Fixtures are specialized tooling systems designed to hold each control arm component in the exact same position every time. This is essential for robotic welding because the robots rely on perfect part placement to produce consistent welds.
During this stage:
- Tubes are cut and notched for precise fitment
- 3D-printed gauges verify consistency of each component
- Fixtures are built to hold parts securely for robotic welding
Consistency is everything. When every part is positioned exactly the same, the robotic welding process can deliver reliable and repeatable results.
Robotic Welding: Precision and Efficiency
Once the fixtures are ready, the parts move to the robotic welding stations. Each robotic system must be carefully programmed before production begins. Programming a single part can take up to a week, but once the process is dialed in, the robots can produce parts quickly and consistently.
During production:
- Multiple fixtures hold left and right control arms simultaneously
- The robot completes several welding operations across multiple stations
- A full production cycle for a pair of arms can take about 45 minutes
This combination of automation and precision ensures every weld is consistent across every part.
Advanced Welding Techniques for Strength and Appearance
CPP uses a welding technique known as stitch pulse MIG welding. This process rapidly pulses the weld on and off during the weld cycle.
The benefits include:
- Reduced heat buildup to prevent warping
- Deep weld penetration for strength
- Cleaner weld appearance similar to TIG welding
The result is a strong, reliable weld with a clean “stack-of-dimes” appearance that enthusiasts appreciate.
Quality Control and Powder Coating
After welding is complete, every control arm goes through quality control inspection. This step ensures that:
- Weld integrity meets CPP standards
- Dimensions and fitment are correct
- Each component meets strict performance requirements
Once the part passes inspection, it moves on to powder coating. This durable finish protects the steel from corrosion while giving the control arms a clean, professional appearance.
Final Assembly In-House
When the powder-coated components return to the facility, CPP completes the final assembly in-house. This includes installing key components such as:
- Ball joint cups
- Pivot barrels and bushings
- Additional hardware depending on the application
After assembly, the finished control arms are ready to be installed on classic vehicles ranging from Tri-Five Chevys to C10 trucks and other classic Ford and GM platforms. From digital design to robotic welding and final assembly, every step of the manufacturing process is designed to deliver consistent quality and performance.
For classic car and truck enthusiasts, this means suspension components that offer:
- Improved strength compared to factory arms
- Precise fitment for classic platforms
- Modern manufacturing quality
- Made-in-America craftsmanship
Whether you're restoring a classic vehicle or building a performance restomod, properly engineered suspension components are a critical part of the build.
