Mechanical construction of the 805 MHz side-coupled cavities for the Fermilab Linac Upgrade

The manufacturing processes for the Side Coupled Structures (SCS) are intimately connected with their tuning requirements. Present Computer Numerical Controlled machining allows very repeatable accuracies of dimensions. This has led to a manufacturing sequence which reduces the need for repeated machining step. Surface tolerances in the high field region of the accelerating cells were assured. Tuning steps were reduced at all stages of construction. This paper will describe the mechanical steps used to fabricate the SCS structure at Fermilab.