Modeling

For modeling we are using a fully functioning package of SolidWorks. SolidWorks has been very easy for beginners to pick up and it has also proven to be extremely powerful. The Cosmos package has proven to be very beneficial in designing components. We are able to quickly optimize parts to reduce weight and increase strength.

Here is a simple bracket that was analyzed.

Here is the result of the Cosmos study. After the optimization routine the part was roughly half the weight of the original design and about 1.5 times stronger!

Here is a model of the chassis design showing both the carbon fiber monocoque lower chassis and the support tubing on the upper section.

After a quick rendering in PhotoWorks we get to see what it might look like when all completed!

Suspension Design

Lotus Engineering Software was kind enough to send us a copy of their design software for us to use in designing our car. This software has components to design crankshafts, cams, connecting rods, suspensions and much more. The software allows the user to quickly develop a suspension system that fits their particular needs. For us we designed the suspension to have zero bump steer, roll centers that coincide front and rear and also have progressive camber rates. Of course this is not all of the design parameters, we have to keep some of it secret, but this shows the power of the software.

Here is the working environment for the software. you can click on any suspension point and move it and get real time feedback on what moving that point affects.

The software will also quickly populate graphs for any parameter that the user defines.

Camber through jounce and rebound

Bump steer, toe angle between front tires through bump

Roll Center position through bump

Honda Breaths Fire

We acquired a new engine and after doing some tear down and inspection we have determined that it is good. All of the internal components looked great, which was a relief to the engine team. The electrical team, Brett and Josh Nell, spent a few days studying the electrical harness off the bike and then developed a new harness that utilizes the stock engine sensors. Before the engine would run a minor change needed to be made with the cam sensor wheel. The stock bike has a three tooth wheel and we required a single tooth wheel, but a few minutes on the Wire EDM and the offending extra teeth were pitched into the garbage can.

Here you can see the cam wheel on the end of the left cam.

Here Brett torques the cam retaining bolts and Josh Nell (background) puts the final touches on the engine control software.

After the engine was wired the engine team took over and buttoned up the last components and calibrated all of the sensors. Because we are still waiting for our fuel cell to be completed the engine team had to get creative on how to deliver fuel to the engine. 15ft of fuel hose connected between Ben's Supra's fuel pump and the fuel rail on the Honda fixed the fuel dilemma.

Just as the engine team had predicted, and the rest of the team hoped, the engine started as soon as fuel made it to the fuel rail. The Honda engine makes a great sound when there are no headers on it!

Laying Up the Nose Mold

After completing all of the bucks it was time to do some major cleaning in the storage unit to convert it from a sophisticated paint booth to a world class clean room for composites lay up. After cleaning up we started laying up the mold for the nose.

Here Brett and Josh S. are applying the tooling surface coat to the buck. This surface coat will stay with the mold when removed to give us a durable surface.

Here is the hard part.... Use your imagination to visualize what laying up a fiberglass mold would look like. Because at this point we are very busy and very sticky, so using a camera is out of the question. Sorry...

Back with clean hands and fresh gloves we vacuum bag the mold to remove excess resin and to compact the fiberglass layers to reduce the internal voids, giving us a stronger and lighter mold.

Here the vacuum bag is now completely sealed and we are starting to remove air from the bag

After some of the air is removed we need to create pleats so that there is no possibility of the vacuum bag bridging over an internal corner. You can see Guy hard at work inspecting the pleats, he is our certified pleat master.

On this mold we achieved a perfect seal as the pump is drawing it's maximum vacuum, 18 in Hg or -60 kPa!

Finishing the Last Buck

McNees Enterprises finished bending our tubing for the front and main roll hoops.




Here is the body after it's final coat of primer.

After a late night at the storage unit sanding to 1200 grit, sealing and applying mold release we completed the body buck.

The finished product. Have to thank Ben Smith for coming by and helping.

More Buck Progress

Guy and Tyler are making quick work of the newly machined body with the loaned DA sanders




Brett and Andrea are putting the final sanding touches on the chassis. You can see our sophisticated paint booth behind them.

The chassis in it's finished state.

What the Rockies look like through polished primer!

Lots of Progress

The body being machined out at Rocky Mountain Composites



Check out the video!


The surface on the nose was finished to mirror quality, really impressive when you realize that the paint is flat gray primer!




The chassis buck is getting paint and sand paper. A friend came over and saw we were sanding by hand with sanding blocks so the next day he showed up with electric DA sanders! Needless to say, progress really sped up! Thanks Bobby!