A pilot assembly includes a base having a cylindrical side wall which holds an electrode subassembly and glass preforms in place for fusing the glass to secure the electrode subassembly to the base. Prior to fusing, a spark electrode is assembled by inserting it into a metal clip receptacle held in a ceramic insulator body forming a part of the electrode subassembly. A pilot tip and orifice subassembly are secured to the base. Fusion of the glass and brazing of the metal including the high tension clip to bring it to spring temper for connection to a plugged wire are accomplished in a single step of heating. The pilot tip includes a locator member which holds the spark electrode in place during fusing and establishes the spark gap. It is removed after fusing. A connecting flange of a bracket is then positioned relative to the side wall of the base to achieve a desired angular disposition, axial orientation and height adjustment of the base relative to the bracket; and the bracket is welded to the side wall of the base. Thus, the same structural elements can be used for many different models of a gas pilot assembly without the need for special parts or process steps for manufacture.