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Chassis Update 05/10

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

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Driver Control

The driver control team took responsibility for steering, pedals, brakes, clutch, gear shift and also the wheel hubs.

At this stage, everything required has been manufactured, and parts are being fitted to the car.

The first job was to select the brakes. After the problems of last years team, we chose to go for outboard rear brakes, so four sets of calipers and discs were ordered from AP Racing.

Now these were selected, the custom front hubs could be designed. The plan was to decrease the weight, by using smaller wheel bearings and a better hub design. They were manufactured from solid aluminium. This is the finished article:

Front Hub

 A new pedal platform was created with an easily adjustable sliding mechanism. This was manufactured from an aluminium plate, on aluminium runners, making a far lighter system than before:

Pedal Platform

An hydraulic clutch system has been implemented to overcome problems with the cable last year. The pipework for this system and the braking system has been kindly supplied by our sponsors BMRS.

The steering system has also been improved, with a different placement of the steering rack, and new Ackerman geometry to improve the car's handling. A lighter aluminium rack and pinion was also sourced:

Rack

Having the mounting points built into the design has also made it a much easier fit onto the car.

Our next stage is the assembly of all the parts we have, ready for testing the car in a few weeks.