Chassis Progress 12/09

Since the last update, the chassis has been completed, with only small mounts left to be added. The finished chassis came together just after Christmas, then suspension and engine mounts were added. The complete frame weighed in at 30kg, with mounts, an decrease of 8kg over last year.
The process of welding the chassis continued, with a number of different jigs being used:

With the frame complete, the suspension mounts had to be added. These were set at angles specified by the suspension team and welded to the frame.

And then engine mounts.

The next stage for us is to paint the chassis once the final mounting points are on, and then assemble the car

Featured Image

Body Work

The body of the new car has been completely redesigned using CFD and windtunnel analysis. The finished design is below:

Again the body will be constructed from carbon fibre. The moulds have been manufactured, and the materials are in, ready for the bodywork to be made once exams are over.

Alex Hodson undertook the task of designing/building the bodywork this year as his 3rd year project. A lot of effort went into creating an aerodynamic shape, whilst also making a good looking car.

The process began with some simple concepts and 2d designs on the computer. These were analysed in Fluent (a CFD program) with a final concept being made into a 3d computer model.

More extensive analysis was then carried out, helping to shape the bodywork to provide the best shape to reduce drag and divert airflow to the radiators to keep the engine cool. Wind tunnel testing was also done on a scale model created on our 3d printer.

From all the analysis, a design was finalised, and moulds created. Here's a video of the cutting process: