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Custom Tube Forming and Fabrication
of Headers, Manifolds, Return Bends, Multi-Bends,
Extrusions, Intrusions, & Brazed Assemblies

Tube Shearing of a Brass Horn Ring Connector for the Automotive Industry

Brass Horn Ring Connector
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At A/C Fabricating Corp., we are dedicated to serving our customers efficiently while maintaining consistent production standards. Since 1975 we’ve built a reputation in the industry for competitive pricing, prompt delivery, customer satisfaction. In this project, a prominent Midwest automotive customer was producing brass horn connectors via raw sheet stamping. They soon realized that the current process was cost prohibitive and may have an impact on overall part quality. Turning to our team at A/C Fabricating, they requested our team to manufacture the very same product out of brass tubing with an emphasis on lower cost and higher quality. The part required a diameter of 1.187” with a length of 1.813” and wall thickness of only 0.020”. It was also required to have an average weight of 0.084 lbs.

Using several processes including a punch press, tube shearing, and end forming, we were able to start producing brass horn connectors in less than 6 weeks with a maximum tolerance of + 0.002” and we produce 79,000 pcs over the life of the product. Our in-house testing utilized gage inspection to confirm all parts adhered to exact customer standards. Our team manufactured all of the brass horn connectors at lower cost and with an emphasis on higher part quality. To learn more about this project, or the processes used to manufacture it, see the table below or contact us directly.

Horn Connector Specifications

Project Name & Description
Horn Connector
Capabilities Applied/Processes
Tube Shearing
End Forming
Equipment Used to Manufacture Part
Punch Press
Overall Part Dimensions
Diameter: Ø 1.187 in
Length: 1.813 in
Wall Thickness: 0.020 in
Estimated Part Weight: 0.084 lbs
Tightest Tolerances
± 0.002 in
Material Used
Industry for Use
In Process Testing/Inspection Performed
Gage Inspection – Check Gages & Sample Gaging
Volume: Life of the Product
First Pat/Turnaround Time
6 weeks
Delivery Location
Standards Met
Customer Specifications

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