Inside the Manufacturing Process: How CPP Tubular Control Arms Are Built in the USA

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From Design to Finished Part: How CPP Tubular Control Arms Are Manufactured​

When upgrading the suspension on a classic car or truck, the quality of the components you choose makes a major difference in performance, reliability, and long-term durability. At Classic Performance Products (CPP), many suspension components are designed and manufactured using modern engineering technology combined with American manufacturing expertise.

Let’s take a look behind the scenes at how CPP tubular control arms move from concept to finished product through a carefully controlled production process.

Step 1: Engineering and Digital Design​

Every suspension component begins in the engineering department, where the original part is carefully analyzed and digitally recreated.

Using advanced CAD software such as SolidWorks, engineers scan and model the control arm to create a precise digital version of the component. This process allows the team to:

  • Reproduce accurate suspension geometry
  • Improve overall strength and durability
  • Create detailed manufacturing files for production
Once the digital design is finalized, 3D printed prototype parts are produced. These prototypes help engineers confirm fitment and evaluate how the individual pieces will work together during assembly.

Step 2: Preparing the Components​

After the design phase is complete, the manufacturing team begins preparing the individual parts that make up the control arm.

This stage involves:

  • Cutting and bending the steel tubing
  • Notching the tube ends for proper fitment
  • Verifying each piece using 3D printed check gauges
These gauges ensure every component is produced with consistent dimensions before entering the welding stage.

Consistency is critical because the next step involves robotic welding systems that rely on precise part placement.

Step 3: Building Fixtures for Robotic Welding​

Before robotic welding can begin, specialized fixtures must be built.

Fixtures are custom tooling systems that hold the control arm components in the exact position required for welding. Because robotic welding relies on repeatability, these fixtures ensure every part is located in the same place during each weld cycle.

Accurate fixtures allow the robotic welders to produce consistent weld quality across every control arm produced.

Step 4: Robotic Welding Production​

Once the fixtures are completed and installed, the control arms move to the robotic welding stations.

Each robotic welder must first be programmed to follow the exact welding path required for the part. Programming a robotic welding sequence can take several days, but once completed, the robots can run production continuously with high precision.

In the welding cell:

  • Fixtures hold left and right control arms simultaneously
  • Multiple stations complete different weld operations
  • A full production cycle can weld a pair of control arms in about 45 minutes
This automated process ensures every weld is consistent from one part to the next.

Step 5: Stitch Pulse Welding Technology​

CPP uses a welding technique called stitch pulse MIG welding for many suspension components.

This process rapidly pulses the weld on and off while welding. The advantages include:

  • Reduced heat buildup in the metal
  • Less risk of part distortion or warping
  • Strong weld penetration
  • A cleaner weld appearance similar to TIG welding
The result is a strong, high-quality weld that maintains the structural integrity of the control arm.

Step 6: Inspection and Finishing​

After welding is completed, every control arm goes through quality control inspection.

This step ensures the part meets CPP’s standards for:

  • Structural integrity
  • Dimensional accuracy
  • Overall build quality
Once approved, the control arms are sent out for powder coating, which provides a durable protective finish and helps prevent corrosion.

Step 7: Final Assembly​

After the powder coating process is completed, the parts return to CPP for final assembly.

During this step, technicians install components such as:

  • Pivot barrels
  • Ball joint cups
  • Additional hardware depending on the application
The completed control arms are then packaged and prepared for installation on classic vehicles.

Suspension Solutions for Classic Cars and Trucks​

CPP manufactures suspension components for a wide range of classic vehicles, including:

  • Chevy C10 trucks
  • Tri-Five Chevrolets
  • Classic GM muscle cars
  • Various classic Ford platforms
Each product is engineered to deliver improved handling, strength, and reliability for both restoration projects and performance builds.

Built for Performance and Reliability​

By combining modern engineering tools, robotic welding technology, and strict quality control procedures, CPP produces suspension components designed to meet the needs of classic car and truck enthusiasts.

From the first digital model to the final assembled product, every step in the process is focused on delivering consistent quality and dependable performance.

Explore More Suspension Upgrades​

If you're planning a suspension upgrade for your classic vehicle, CPP offers a full line of steering, brake, and suspension solutions designed for performance and ease of installation.

Visit ClassicPerform.com to learn more and find the right components for your build.
 
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