Binghamton University SAE Supermileage
Senior Design Project WCP45
Tuesday, May 6, 2014
Saturday, May 3, 2014
Friday, April 25, 2014
Building the Chassis
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.
Here you can see Mike and Nick cutting all of the aluminum tubing to the correct lengths and angles.
All of the components placed on top of the wooden mock up chassis.
The chassis getting welded.
Rear components bolted up to the chassis.
Nick holding the chassis on top of the underside of the body to make sure they will fit together.
Jig specifically built to weld the foot bar together.
Wednesday, April 23, 2014
Building the Body
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.
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.
The sections were glued together using liquid nails or epoxy and then clamped.
Azim and Mike sanding down the nose of the plug.
Using straps, the remaining larger foam sections were glued together.
The fiberglass was then grinded down to remove all the high spots on the surface.
Here you can see the test plug and full size plug side by side.
Multiple coats of plaster were used to produce a smooth finish.
Due to the amount of gaps on the bottom of the plug, our team decided to fiberglass this as well.
Body Test Plug Built
Test plug prepped and ready to start laying up carbon fiber on various surface coatings.
Figure 1. Plug was created using various foam cross sections that were glued together.
Figure 2. Foam after sanding
Figure 3. Plaster applied to outer surface of foam to create a smooth surface.
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