How to Weld Quarter Turn Dzus Tabs onto Roll Cage Tubing

How to Weld Quarter Turn Dzus Tabs onto Roll Cage Tubing

Whether you're mounting aluminum body panels, interior tins, or custom access doors, Dzus tabs are a racecar fabricator’s best friend. They're small, lightweight, and when installed properly, allow for fast panel removal and solid retention. But welding Dzus tabs to round roll cage tubing can be a bit tricky—especially when you're trying to get them positioned just right.

Here’s a step-by-step guide to get it done right the first time.

🔧 Tools & Materials You’ll Need

  • Dzus tabs (steel or aluminum, depending on your setup)
  • Dzus buttons and springs (matched to tab size)
  • Roll cage tubing (typically 1.250", 1.500", or 1.625" DOM or chromoly)
  • Chassis Speed Jig or Dzus tab locator (optional but highly recommended)
  • MIG or TIG welder (depending on your tab/tube material)
  • Angle grinder with flap disc
  • Center punch and hammer
  • Clamps or magnets
  • Safety gear (gloves, helmet, jacket)

Step 1: Prep the Tubing

Start by cleaning the section of tubing where your Dzus tab will mount. Use a flap disc or wire wheel to remove paint, rust, or mill scale. You want shiny, bare metal for a solid weld.

👉 Pro Tip: If you're mounting to chromoly, use acetone to clean the area thoroughly—it's sensitive to contamination.

Step 2: Fit the Tab to the Tube

Dzus tabs are flat, but roll cage tubing is curved. That means you’ll either:

  • Grind a saddle into the back of the tab to match the tube diameter, or
  • Use a pre-cut tab with a tube-specific curve (huge time-saver)

Line it up where you want it and check that the tab lays flush. A poor fit means a weak weld.

Step 3: Use a Jig or Fixture

Holding a Dzus tab in place while tacking is like threading a needle with oven mitts—unless you're using a Speed Jig. A jig like the Dead Hand Solutions Chassis Speed Jig can clip onto your tubing and hold the tab in perfect position, hands-free.

  • No more tape, magnets, or guessing.
  • Perfect alignment every time—horizontal, vertical, even upside down.

If you're not using a jig, at least use clamps and a center punch to make sure the hole placement is accurate.

Step 4: Tack Weld

With your tab in place:

  1. Set your welder for thin gauge material (typically 0.060"–0.125").
  2. Tack both sides of the tab with quick, clean tacks.
  3. Check alignment again before fully welding.

👉 If your tab warps during tacking, stop and refit before continuing.

Step 5: Fully Weld the Tab

Once it’s tacked and aligned:

  • Weld all the way around, or just stitch weld depending on your spec.
  • Avoid overheating thin tabs—they’ll warp fast and lose strength.
  • If you’re TIG welding, aim for a consistent bead with low amperage.

If you’re doing a lot of tabs, take your time and avoid stacking heat into one area.

Step 6: Test Fit Your Panels

Before moving on, always test fit the Dzus button and spring with your panel. Make sure:

  • The tab hole lines up with the spring hole
  • The panel sits flush with the tubing
  • The button has proper tension and clicks securely

Small tweaks now save big headaches later.

Final Thoughts

Installing Dzus tabs is one of those tasks that separates a clean chassis build from a hacked-together mess. With the right prep, a jig for precision, and some patience, you’ll get tabs that look sharp and perform even better.

If you're doing more than a few, consider investing in a tool like the Chassis Speed Jig—especially if you're working one-handed or solo. It'll save you time, sanity, and give you perfect repeatable results.

Need Dzus tab jigs or precision fab tools?
Check out DeadHandSolutions.com for game-changing tools built by fabricators, for fabricators.

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