tag:blogger.com,1999:blog-42858967575029280852024-03-04T23:21:06.433-08:00Binghamton University SAE SupermileageSenior Design Project
WCP45Anonymoushttp://www.blogger.com/profile/18416802200336075457noreply@blogger.comBlogger6125tag:blogger.com,1999:blog-4285896757502928085.post-42155616005789751922014-05-06T14:08:00.003-07:002014-05-06T14:08:56.001-07:00Laying Up The Carbon Fiber<embed width="600" height="361" type="application/x-shockwave-flash" allowFullscreen="true" allowNetworking="all" wmode="transparent" src="http://static.photobucket.com/player.swf" flashvars="file=http%3A%2F%2Fvid306.photobucket.com%2Falbums%2Fnn274%2FInformer291%2Fsupermileagefb_zps22ad47f9.mp4&title=">Anonymoushttp://www.blogger.com/profile/18416802200336075457noreply@blogger.com0tag:blogger.com,1999:blog-4285896757502928085.post-49455743019742102222014-05-03T19:06:00.001-07:002014-05-03T19:06:28.689-07:00Plug Primed!<p dir="ltr">Plug Primed and almost ready for carbon fiber.</p>
<div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGXEWcqNtrhj5Ud297trhOSKrzf_3skf4WA5jLqaAuRAWFaixAwQkdkR19cCn5SLovc1lCwJ0uR0sXZzZH2JLKrhh1Mj8z_MIDgKFOdz6Ph6re2exgvWllGw_4rQ_sc14UUxyeoijSMaE/s1600/20140502_201149.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"> <img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGXEWcqNtrhj5Ud297trhOSKrzf_3skf4WA5jLqaAuRAWFaixAwQkdkR19cCn5SLovc1lCwJ0uR0sXZzZH2JLKrhh1Mj8z_MIDgKFOdz6Ph6re2exgvWllGw_4rQ_sc14UUxyeoijSMaE/s640/20140502_201149.jpg"> </a> </div>Anonymoushttp://www.blogger.com/profile/18416802200336075457noreply@blogger.com0tag:blogger.com,1999:blog-4285896757502928085.post-26206125267009844062014-05-03T19:02:00.001-07:002014-05-03T19:02:30.605-07:00Testing the ChassisVideo and images of testing the chassis for turning radius and overall functionality.<br />
<div class="separator" style="clear: both; text-align: center;">
<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dzvsZecaLt6lTlNUuH1PW68aGYMdb4EFqS9J-dfWbCJBjBw10o6U2nOBM8sG2OVggh6ZEY6s7SwjQHLrzLV5Q' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtCgk35hmLb4xvdO8ohyphenhyphenaw9ExUKay-MXs9KLO8IAmH08qimwf3STXZUs4a0pMO_WXXf7WXp6f1O6rO1IqEth1FaEo8HT5_zQMgdHJGIazClzDqF_BWR26M9_MX_-48P8H-t0zMwzrQ9rw/s1600/20140502_192714.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtCgk35hmLb4xvdO8ohyphenhyphenaw9ExUKay-MXs9KLO8IAmH08qimwf3STXZUs4a0pMO_WXXf7WXp6f1O6rO1IqEth1FaEo8HT5_zQMgdHJGIazClzDqF_BWR26M9_MX_-48P8H-t0zMwzrQ9rw/s1600/20140502_192714.jpg" height="240" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj50aNcYJFOdzn_N68L-NMQyjyd2_PikzETLkfWnNUxzh-wh_t4Bm-SzdG4ggkMLngc95dOW5J57Soql6qJpDcY4Rq2rqzWKv4YOKXlgSG0qhLiOJf63YGrfJnO7NsQHx0zK3C_y6SOxDw/s1600/20140502_193155.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj50aNcYJFOdzn_N68L-NMQyjyd2_PikzETLkfWnNUxzh-wh_t4Bm-SzdG4ggkMLngc95dOW5J57Soql6qJpDcY4Rq2rqzWKv4YOKXlgSG0qhLiOJf63YGrfJnO7NsQHx0zK3C_y6SOxDw/s1600/20140502_193155.jpg" height="240" width="320" /></a></div>
Anonymoushttp://www.blogger.com/profile/18416802200336075457noreply@blogger.com0tag:blogger.com,1999:blog-4285896757502928085.post-25698622556483647922014-04-25T17:13:00.002-07:002014-05-03T19:04:07.079-07:00Building the Chassis<div class="separator" style="clear: both; text-align: left;">
Our chassis is made entirely out of aluminum 6061 square and rectangular tubing. The components necessary to bolt the wheels to the chassis and calipers were sent out to be machined. Overall it was designed to be as stiff as possible while also being light weight. </div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0Z8pS0FGu-wytuwe39yig1w7_5eBKi6-VUJYBgJf5P0qnqgyXBaX6cGQKOItt9wZOGvWCgkEfMhVqd_9ALeGe8rEOXEDaFAMUwkRVlrTO7YPPrvz-CpHRts8mwEH8mmsm56dHmvWhKGw/s1600/20140412_164333.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0Z8pS0FGu-wytuwe39yig1w7_5eBKi6-VUJYBgJf5P0qnqgyXBaX6cGQKOItt9wZOGvWCgkEfMhVqd_9ALeGe8rEOXEDaFAMUwkRVlrTO7YPPrvz-CpHRts8mwEH8mmsm56dHmvWhKGw/s1600/20140412_164333.jpg" height="240" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-uzzpOHCguSauujz9zAkKsx3kuBX0EJwg21Df0AuJn8BXxYiPuR845kgk6NiB0Bb6ngF9T5q97A3lbgt5d0dre72Xd-ZHHmdZtFj0YPsJamb7Sca2T9yTaajYZO78EP_Iz_UPF4OVbNQ/s1600/20140412_194002.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-uzzpOHCguSauujz9zAkKsx3kuBX0EJwg21Df0AuJn8BXxYiPuR845kgk6NiB0Bb6ngF9T5q97A3lbgt5d0dre72Xd-ZHHmdZtFj0YPsJamb7Sca2T9yTaajYZO78EP_Iz_UPF4OVbNQ/s1600/20140412_194002.jpg" height="240" width="320" /></a></div>
Here you can see Mike and Nick cutting all of the aluminum tubing to the correct lengths and angles.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOAp5-oaUSjnjgCyVXEoFdkuOloAJp2wLXW3GsQXezc2WzogNqpWvUyNPcopD-yaTVplUBxdFx4_qClKGTSyhss9sozv1bxq8CrdjbzSBPDBliBC927MdbCsIWFVsPPkdqednKCzBAlAQ/s1600/DSC_0100.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOAp5-oaUSjnjgCyVXEoFdkuOloAJp2wLXW3GsQXezc2WzogNqpWvUyNPcopD-yaTVplUBxdFx4_qClKGTSyhss9sozv1bxq8CrdjbzSBPDBliBC927MdbCsIWFVsPPkdqednKCzBAlAQ/s1600/DSC_0100.JPG" height="320" width="212" /></a></div>
All of the components placed on top of the wooden mock up chassis.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVyjvS96V9bt92nULLM7Sih2Q9oXtfBUDV-JXrP41_OLlRoqhSeQ_UCcnlXVcF3Z8DmxDC2rUcZzA11BfezJaxZM0AQckjyv1Dx7E_GbKBQhjSahi_jLFTKqvbvaJOgSpqfPyms5sHcTg/s1600/DSC_0149.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVyjvS96V9bt92nULLM7Sih2Q9oXtfBUDV-JXrP41_OLlRoqhSeQ_UCcnlXVcF3Z8DmxDC2rUcZzA11BfezJaxZM0AQckjyv1Dx7E_GbKBQhjSahi_jLFTKqvbvaJOgSpqfPyms5sHcTg/s1600/DSC_0149.JPG" height="320" width="212" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgoCvvlKlhhG9DGHSMa1EKJ1ro1Zx-M4dU7t0r6OSkuTVczoSH92QmJWcleI6LjFFws3cU1575zf_E4NX4YqzeZbtWUA0GqlK2wnQWjOaxcfK6679WOZFtN3luuJTxG-uxmxHSlvyF9XN0/s1600/DSC_0158.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgoCvvlKlhhG9DGHSMa1EKJ1ro1Zx-M4dU7t0r6OSkuTVczoSH92QmJWcleI6LjFFws3cU1575zf_E4NX4YqzeZbtWUA0GqlK2wnQWjOaxcfK6679WOZFtN3luuJTxG-uxmxHSlvyF9XN0/s1600/DSC_0158.JPG" height="212" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiV_Spwh3BcbzN6mRRteffu6FoUcUqEQghMA_oD9hLiRi2dzrYXyT9Dun8B5uqv0z7SMPOD_lSmBgwkEO04acPz02l3DqPxX3L6MwN848p2x7Q4gZoOQFBwBTScB0AI1whVZF6zdfqg2Nc/s1600/DSC_0159.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiV_Spwh3BcbzN6mRRteffu6FoUcUqEQghMA_oD9hLiRi2dzrYXyT9Dun8B5uqv0z7SMPOD_lSmBgwkEO04acPz02l3DqPxX3L6MwN848p2x7Q4gZoOQFBwBTScB0AI1whVZF6zdfqg2Nc/s1600/DSC_0159.JPG" height="212" width="320" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
The chassis getting welded.</div>
<div class="separator" style="clear: both; text-align: left;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihyphenhyphenJWXhcrUyZnAzrLepsdCsNEVz_w9yz2fMVXtOuicfGkbY66YWTrMxxhSU6Ft2mKdwomJzrBdEabI7PJ081w4VlzZmxhOwOngGcNiwgqYEqY4bmwwQyVq_xwpKFU0LWksY8FqX5Kur00/s1600/20140413_201319.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihyphenhyphenJWXhcrUyZnAzrLepsdCsNEVz_w9yz2fMVXtOuicfGkbY66YWTrMxxhSU6Ft2mKdwomJzrBdEabI7PJ081w4VlzZmxhOwOngGcNiwgqYEqY4bmwwQyVq_xwpKFU0LWksY8FqX5Kur00/s1600/20140413_201319.jpg" height="240" width="320" /></a></div>
Here you can see all of the pieces that were sent out for machining.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUE1oOCAIfv-_DGN7VhMBxTkYK82GgaWUwy1gKtAH4HT0kfEJW_M7bdag6vRHmSDmccPJJEMgostD5k1h1dqJOfWcg0dTaJ6XPPZTCwUbRZVczOmL-7A1yF7cpXh8pTBGSmoyY1h6M_uo/s1600/DSC_0179.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUE1oOCAIfv-_DGN7VhMBxTkYK82GgaWUwy1gKtAH4HT0kfEJW_M7bdag6vRHmSDmccPJJEMgostD5k1h1dqJOfWcg0dTaJ6XPPZTCwUbRZVczOmL-7A1yF7cpXh8pTBGSmoyY1h6M_uo/s1600/DSC_0179.JPG" height="212" width="320" /></a></div>
Rear components bolted up to the chassis.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9ShBg1qNZIHjTBANtjvtGNeUPog1GGXOh3r3YzBN9bxBAWW4sOxNL1ZcRN9G-X7bCAXjRnXrkzz1sWZ2z2ZLt2j7Q2Dk7C3iZzbweCsExroBzpJPey1CHUPn0KV62BmeW8nai5-s08lM/s1600/DSC_0214.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9ShBg1qNZIHjTBANtjvtGNeUPog1GGXOh3r3YzBN9bxBAWW4sOxNL1ZcRN9G-X7bCAXjRnXrkzz1sWZ2z2ZLt2j7Q2Dk7C3iZzbweCsExroBzpJPey1CHUPn0KV62BmeW8nai5-s08lM/s1600/DSC_0214.JPG" height="212" width="320" /></a></div>
Nick holding the chassis on top of the underside of the body to make sure they will fit together.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFbT4lkwHQA-EfqMhTI0IpJBv9KBWH_xLFEeRwcyJY3kQvFxTUQp0eG20TSSSL2Tq1OOorDLqCyG7DAcn4BrDgOVR78hA5k6NEhwcRDUUnapYJP33mP2-NE7PSu41pu4dSIxeY88KM5RY/s1600/DSC_0240.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFbT4lkwHQA-EfqMhTI0IpJBv9KBWH_xLFEeRwcyJY3kQvFxTUQp0eG20TSSSL2Tq1OOorDLqCyG7DAcn4BrDgOVR78hA5k6NEhwcRDUUnapYJP33mP2-NE7PSu41pu4dSIxeY88KM5RY/s1600/DSC_0240.JPG" height="212" width="320" /></a></div>
Jig specifically built to weld the foot bar together.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6qX33-hzdxbGcpMENFMVuMsZJFSEMNgUGez15W4sbj3mWF30rrWFncHaSjLTuTCrZhINw7ayytniAJvU7fQb0Yirsc2edWL1lc8R0Pu7oJ9nF0phSjqa1enVVnKPR18_s7EAf-HrnVF0/s1600/20140423_170717.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6qX33-hzdxbGcpMENFMVuMsZJFSEMNgUGez15W4sbj3mWF30rrWFncHaSjLTuTCrZhINw7ayytniAJvU7fQb0Yirsc2edWL1lc8R0Pu7oJ9nF0phSjqa1enVVnKPR18_s7EAf-HrnVF0/s1600/20140423_170717.jpg" height="240" width="320" /></a></div>
<br />Anonymoushttp://www.blogger.com/profile/18416802200336075457noreply@blogger.com0tag:blogger.com,1999:blog-4285896757502928085.post-74421543017665109462014-04-23T20:58:00.002-07:002014-04-23T20:58:52.470-07:00Building the Body<div class="separator" style="clear: both; text-align: left;">
Building the body has become the most challenging task for our team. There are a total of 72 cross sections that needed to be cut out of foam and fit together. </div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8FMtclhOm2KHOyIYDHmdlKFIWnBrmmDyXl9Ugv48tsS4keIzrIe74V6huwGf27hucYZzTYqGYX9StGfMbIpkGvjWKgjYUO_5idXKQ_5pzmmr5u66Nj7UvpJ2ItW-wHOzjvykLzW9G8dg/s1600/20140402_193706.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8FMtclhOm2KHOyIYDHmdlKFIWnBrmmDyXl9Ugv48tsS4keIzrIe74V6huwGf27hucYZzTYqGYX9StGfMbIpkGvjWKgjYUO_5idXKQ_5pzmmr5u66Nj7UvpJ2ItW-wHOzjvykLzW9G8dg/s1600/20140402_193706.jpg" height="240" width="320" /></a></div>
In the photo above you can see the plotter sheets that were printed to used as a guide to cut out all of the sections. The foam that we chose to use is regular insulation foam that you can buy at any Lowes or Home Depot.<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRpBf_OipvlPPQy8dLVRYOqP4w5fCBWOpTEAT1TnfW0hwMolwGufXe23zTIQmgQo8gZonSk1Gflp6GJOA5CVJiButch33wm3PlkuV1JqKCJUI6TB1OUa7-O6AAdqHQF8J6YGNvP-VJuls/s1600/20140406_162510.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRpBf_OipvlPPQy8dLVRYOqP4w5fCBWOpTEAT1TnfW0hwMolwGufXe23zTIQmgQo8gZonSk1Gflp6GJOA5CVJiButch33wm3PlkuV1JqKCJUI6TB1OUa7-O6AAdqHQF8J6YGNvP-VJuls/s1600/20140406_162510.jpg" height="240" width="320" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
We used a jigsaw to cut out all of the sections. We found that this was actually easier and faster then using a band saw or any other machine for cutting. </div>
<div class="separator" style="clear: both; text-align: left;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjevL2i26MviGPiSlq7K3dyyPCcdo3J12SY7M-P87cK-89h6zcT1BqUx_J7vjAa1k9F6cJynEE3xdMV1l_IhCjBMtuV8g1WsXmnb63hyphenhyphenGHi0NdwUZCkRPsuYWQpS79fMu1N121bgj8DYaY/s1600/20140406_174941.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjevL2i26MviGPiSlq7K3dyyPCcdo3J12SY7M-P87cK-89h6zcT1BqUx_J7vjAa1k9F6cJynEE3xdMV1l_IhCjBMtuV8g1WsXmnb63hyphenhyphenGHi0NdwUZCkRPsuYWQpS79fMu1N121bgj8DYaY/s1600/20140406_174941.jpg" height="240" width="320" /></a></div>
In this picture you can see all of the cross sections loosely placed together after cutting was finished.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4mKqEbtRZQ5j2gIrZdOJuJUY-QKSH8B_ZqWPQRJ_tiC_7zKAusxy5aBsaF4OFEmCsVP-BSaFuWiQiaTpV1-EaVYJ6vt3SPDKcz7s9xFgRg9QZkmboC2SQ4wZg0jP5WZf-pfnS_tUBYF8/s1600/20140407_201137.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4mKqEbtRZQ5j2gIrZdOJuJUY-QKSH8B_ZqWPQRJ_tiC_7zKAusxy5aBsaF4OFEmCsVP-BSaFuWiQiaTpV1-EaVYJ6vt3SPDKcz7s9xFgRg9QZkmboC2SQ4wZg0jP5WZf-pfnS_tUBYF8/s1600/20140407_201137.jpg" height="240" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwifIq07HVkvoVX_QR9CTPVrwodpE7868kFB6bUlYUPv2iLnUYNSB5l7OD-hjSh3oHdb0YgqtpN3HBbpenSMqXmoPKXdPUJ8pu7PFkf4AKMHuuGNBsT6GYXQk51qhkxF93emQw0SQDl9M/s1600/20140407_202622.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwifIq07HVkvoVX_QR9CTPVrwodpE7868kFB6bUlYUPv2iLnUYNSB5l7OD-hjSh3oHdb0YgqtpN3HBbpenSMqXmoPKXdPUJ8pu7PFkf4AKMHuuGNBsT6GYXQk51qhkxF93emQw0SQDl9M/s1600/20140407_202622.jpg" height="320" width="240" /></a></div>
The sections were glued together using liquid nails or epoxy and then clamped.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXo0OF40XXuzO_F1PzOQfF5Oi4ZFt10OhMKvCst4rN4u_QGMLj_tNgMSZoyJA-bF5wVjzOrljXjqWrEfkPRoR6z7IfezEvGnBwzWZvS4Zeg0571vZ6M72feyrGwRN6pWcyWoqrp8xb-I0/s1600/DSC_0035.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXo0OF40XXuzO_F1PzOQfF5Oi4ZFt10OhMKvCst4rN4u_QGMLj_tNgMSZoyJA-bF5wVjzOrljXjqWrEfkPRoR6z7IfezEvGnBwzWZvS4Zeg0571vZ6M72feyrGwRN6pWcyWoqrp8xb-I0/s1600/DSC_0035.JPG" height="212" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQ6nvIIfMwFk1vk32vjzgeJUSh6idogCWj_XfG1q6kNyVCPCJB0coGR_H43Cxk7peuH8tkw9MGfgxJy7RQvmfbYwgqH73EQoa2dwrMneFk2GyFEouJJ3aj_F9yECvdFx3q_gaZCge_OzY/s1600/DSC_0039.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQ6nvIIfMwFk1vk32vjzgeJUSh6idogCWj_XfG1q6kNyVCPCJB0coGR_H43Cxk7peuH8tkw9MGfgxJy7RQvmfbYwgqH73EQoa2dwrMneFk2GyFEouJJ3aj_F9yECvdFx3q_gaZCge_OzY/s1600/DSC_0039.JPG" height="212" width="320" /></a></div>
Azim and Mike sanding down the nose of the plug.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtgdjyMcKQxyhhjHvSLORuLU66G-YvY8Rh6cjMqLjVUwAvnHJFpUnVz2Xz36ISw5MGP_ijROgIxFM2fIAufJeXhAPUfxVPjlkBYdaL5c4OPSuGQ8PtTO2-kMGO0ZrRakDIE_pg1rJkFPo/s1600/DSC_0042.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtgdjyMcKQxyhhjHvSLORuLU66G-YvY8Rh6cjMqLjVUwAvnHJFpUnVz2Xz36ISw5MGP_ijROgIxFM2fIAufJeXhAPUfxVPjlkBYdaL5c4OPSuGQ8PtTO2-kMGO0ZrRakDIE_pg1rJkFPo/s1600/DSC_0042.JPG" height="212" width="320" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
Using straps, the remaining larger foam sections were glued together.</div>
<div class="separator" style="clear: both; text-align: left;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPldQPWHRzn_5NSk7fMrS77yysimR698qp77EpNVeXaXnUc8TAubg9tZA-8wtzM845N7ZGu1EKVCqLUVkNSKkpzdNRGOe_tvc8Y4JWkzE86UekWMdthqvFflulzIhvZFs_mkH4bUMi4Uk/s1600/20140412_193958.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPldQPWHRzn_5NSk7fMrS77yysimR698qp77EpNVeXaXnUc8TAubg9tZA-8wtzM845N7ZGu1EKVCqLUVkNSKkpzdNRGOe_tvc8Y4JWkzE86UekWMdthqvFflulzIhvZFs_mkH4bUMi4Uk/s1600/20140412_193958.jpg" height="240" width="320" /></a></div>
We did however run into a problem with the sections coming apart. To solve this issue the outside of the foam was fiber glassed to add additional strength to the plug.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXqV-lZVwAvoVfwBVl6S2-JwgH6gPHhHFgxHWruQR9-z0NUFRALBDfmVcMBR7drCbXkCiEGUEahMTPRv2eafiWVcFaPtnDN-V8uLYSVRd8lvOA-Lwxq-KdkjpOswq-mkOKgM5AmKjg21g/s1600/DSC_0076.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXqV-lZVwAvoVfwBVl6S2-JwgH6gPHhHFgxHWruQR9-z0NUFRALBDfmVcMBR7drCbXkCiEGUEahMTPRv2eafiWVcFaPtnDN-V8uLYSVRd8lvOA-Lwxq-KdkjpOswq-mkOKgM5AmKjg21g/s1600/DSC_0076.JPG" height="212" width="320" /></a></div>
The fiberglass was then grinded down to remove all the high spots on the surface.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3fXId5SfMOspEgq-QtFtt5MIQHrk7ZSUNWsySo_NJMqdjHBZpVQctOy-pe2FpwCTqkXSz9udpLRqJwL6gZs7TEX1W5Gb7GAK5T2C2ikBDNVg8u8r3MoX-7WstuD6rhCXSNGAZ87lWO6Q/s1600/DSC_0093.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3fXId5SfMOspEgq-QtFtt5MIQHrk7ZSUNWsySo_NJMqdjHBZpVQctOy-pe2FpwCTqkXSz9udpLRqJwL6gZs7TEX1W5Gb7GAK5T2C2ikBDNVg8u8r3MoX-7WstuD6rhCXSNGAZ87lWO6Q/s1600/DSC_0093.JPG" height="212" width="320" /></a></div>
Here you can see the test plug and full size plug side by side.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjp5v2k9ahBZiYLWh2TWMwLrThSR4y536Q9zp6tN-X2AypJM_DqBClZ_xgiuQl5j_4uP3-I_6eQuBwUnhAWR-LRBoKaNHA2ULyLKqmRLVr0vuv3rb5rxaml1joAvfDWNLkhyphenhyphen6-QfLXoquQ/s1600/DSC_0116.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjp5v2k9ahBZiYLWh2TWMwLrThSR4y536Q9zp6tN-X2AypJM_DqBClZ_xgiuQl5j_4uP3-I_6eQuBwUnhAWR-LRBoKaNHA2ULyLKqmRLVr0vuv3rb5rxaml1joAvfDWNLkhyphenhyphen6-QfLXoquQ/s1600/DSC_0116.JPG" height="320" width="212" /></a></div>
Multiple coats of plaster were used to produce a smooth finish.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJCJEJmPkD246wT10PwKLHZyPt98OnO2lq8s9rG_QyeyIkwZt4tyg8QoUuE3h1yOZ9j82qj4sgqQSfsdl2JIX8eaI1MyT5xy6g9LGjcKDkTtuFnDV95Zq-RMiH_Gou2CaZ0c7Zkkw9-hQ/s1600/DSC_0120.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJCJEJmPkD246wT10PwKLHZyPt98OnO2lq8s9rG_QyeyIkwZt4tyg8QoUuE3h1yOZ9j82qj4sgqQSfsdl2JIX8eaI1MyT5xy6g9LGjcKDkTtuFnDV95Zq-RMiH_Gou2CaZ0c7Zkkw9-hQ/s1600/DSC_0120.JPG" height="212" width="320" /></a></div>
Due to the amount of gaps on the bottom of the plug, our team decided to fiberglass this as well.Anonymoushttp://www.blogger.com/profile/18416802200336075457noreply@blogger.com0tag:blogger.com,1999:blog-4285896757502928085.post-34622697311963265412014-04-23T18:43:00.002-07:002014-04-23T19:59:55.800-07:00Body Test Plug Built<div class="separator" style="clear: both; text-align: left;">
Test plug prepped and ready to start laying up carbon fiber on various surface coatings.</div>
<div class="separator" style="clear: both; text-align: left;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQ7EbkzXNkFZQ9O9piDnRuWFSSIcJyRSrCAAejAPuEpY0MChGf_GmMCqy9ONEnodxfInejCZKnE7oCe6PKP87qaNGBvNQAoFkGVkSNn7Fu66T0bqpZZtoW-K2WWkjXuPj0ezY7g4onBLM/s1600/20140321_122958.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQ7EbkzXNkFZQ9O9piDnRuWFSSIcJyRSrCAAejAPuEpY0MChGf_GmMCqy9ONEnodxfInejCZKnE7oCe6PKP87qaNGBvNQAoFkGVkSNn7Fu66T0bqpZZtoW-K2WWkjXuPj0ezY7g4onBLM/s1600/20140321_122958.jpg" height="320" width="240" /></a></div>
<div style="text-align: center;">
Figure 1. Plug was created using various foam cross sections that were glued together.</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgm-dxcZfKXX10nu5KcSYSrMILMwSBEvmI2mT76wqRFUMwM6GWQzfj9q7SZkBPP9yZfA9PlRIQ6m-c0BTCH38ShsjEAm225Zm6c8OSYX8PrzjC7gnFMCZ3umMGfdg16HCMrr0EsWfO93kk/s1600/20140321_145710.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgm-dxcZfKXX10nu5KcSYSrMILMwSBEvmI2mT76wqRFUMwM6GWQzfj9q7SZkBPP9yZfA9PlRIQ6m-c0BTCH38ShsjEAm225Zm6c8OSYX8PrzjC7gnFMCZ3umMGfdg16HCMrr0EsWfO93kk/s1600/20140321_145710.jpg" height="320" width="240" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
Figure 2. Foam after sanding</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUt0fvbAoJU1hZx6YeTPvjLh9Gut-AzwpQ5k1aE4AnJZiGzGS6GkljfMPwT_owj3Sra1nmc-dEH_XIh77fTaE7kdlN4_Eynycph0XGNVOXmuUNNYeQyNWNygHu-ih4NqLcmRdSyk_B5PY/s1600/Background.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUt0fvbAoJU1hZx6YeTPvjLh9Gut-AzwpQ5k1aE4AnJZiGzGS6GkljfMPwT_owj3Sra1nmc-dEH_XIh77fTaE7kdlN4_Eynycph0XGNVOXmuUNNYeQyNWNygHu-ih4NqLcmRdSyk_B5PY/s1600/Background.jpg" height="240" width="320" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
Figure 3. Plaster applied to outer surface of foam to create a smooth surface.</div>
Anonymoushttp://www.blogger.com/profile/18416802200336075457noreply@blogger.com0