Go Back OFN Forums > Fabrication > Race Car Fabrication

Race Car Fabrication There is a lot of cool fabriaction going on the race car industry, show us what you got.


Race Car Fabrication There is a lot of cool fabriaction going on the race car industry, show us what you got.

Reply
 
Thread Tools
  #1  
Old 12-13-2006, 10:09 PM
Brian1's Avatar
Brian1 Brian1 is offline
Moderator
 
Join Date: Oct 2004
Location: Albuquerque, NM
Posts: 642
My race car experience

Well I thought I would add my race car experience now that there is a forum dedicated to race cars. For my senior project in mechanical engineering I got involved with a program called Formula SAE, known as FSAE, which is a competition put on by the Society of Automotive Engineers (SAE). I became the chassis team leader and later in the project I became the manufacturing team leader.

The cars are all designed, fabricated and raced by engineering students. There are many competition sites around the world but the main competition is in Detroit, Michigan in May. There are many aspects that are judged such as design, manufacturing, budget, acceleration, autocross and endurance to name a few. The rules allow for many different types of designs including engines but there are restrictions. The engine cant be bigger than 600cc's, there is an air restrictor required the size of a penny and various other rules for wheelbase, track width and chassis design.

The first part of the project was the design. This took about 5 months and the entire car was drawn using Solidworks. The next part was the fabrication which took about 4-5 months.

In order to keep very close tolerances on the tubular components I, along with 2 others, devised a system of jigs for the chassis and a-arms. The chassis jig consisted of 2"x2"x3/16" square tube as the base and 1"x1"x.120" square tube and u-bolts to hold the chassis tubes in place. The entire jig was put on stands that allowed the jig and chassis to rotate 360 degrees for welding purposes. 1"x1" tube was made into clamps using u-bolts. The 1x1 was notched on the mill to exact tolerances according to the CAD model for maintaining distances between tubes. The entire chassis was assembled on the jig before any finish welding occured - it was only tacked in some places.

The chassis was constructed from 1" 4130 tube with .090" wall for the roll hoops and .060" wall for the rest. There is also .5"x.030" 4130 tube used in the front. The entire chassis was notched using various methods (hole saw tube notcher, lathe, mill and grinder). The tubes were purged with argon and then TIG welded. The a-arms and pull/push rods were also constructed from 4130 tube of various diameters depending on the suspension loads.

Many of the components were cut by a water jet company which sponsored us. Tabs, brackets, brake rotors and even big chunks of 7075 Al. were rough cut for machining. We had an in-house CNC mill that we were constantly using to machine our components such as the wheel uprights, spindles, diff extensions, diff carriers and we even prototyped our own throttle body.
Attached Thumbnails
Click image for larger version

Name:	IM007076.jpg
Views:	182
Size:	57.9 KB
ID:	4590   Click image for larger version

Name:	IM007084.jpg
Views:	170
Size:	59.6 KB
ID:	4591   Click image for larger version

Name:	IM007087.jpg
Views:	166
Size:	66.7 KB
ID:	4592  

Click image for larger version

Name:	nn01.jpg
Views:	179
Size:	99.9 KB
ID:	4593  
__________________
Brian
1942 Flatfender Crawler/1991 Explorer Overlander/1991 Explorer Trail Truck

Last edited by Brian1; 12-09-2008 at 02:44 PM.
Reply With Quote
  #2  
Old 12-13-2006, 10:12 PM
Brian1's Avatar
Brian1 Brian1 is offline
Moderator
 
Join Date: Oct 2004
Location: Albuquerque, NM
Posts: 642
Here is a picture of the design in Solidworks
Attached Thumbnails
Click image for larger version

Name:	SW model small.jpg
Views:	127
Size:	27.3 KB
ID:	4594  
__________________
Brian
1942 Flatfender Crawler/1991 Explorer Overlander/1991 Explorer Trail Truck

Last edited by Brian1; 12-09-2008 at 02:58 PM.
Reply With Quote
  #3  
Old 12-13-2006, 10:18 PM
Brian1's Avatar
Brian1 Brian1 is offline
Moderator
 
Join Date: Oct 2004
Location: Albuquerque, NM
Posts: 642
So after the fab work was all done came the fun part, driving it! 0-60MPH in about 3 seconds.

We placed 14th in the World in the 2005 FSAE competition.
Top 20 in the Texas SCCA auto cross event in A-mod
Top 3 local Corvette auto cross event
Attached Thumbnails
Click image for larger version

Name:	DSC00100.JPG
Views:	129
Size:	52.5 KB
ID:	4595   Click image for larger version

Name:	IMG_8178.JPG
Views:	128
Size:	48.2 KB
ID:	4596  
__________________
Brian
1942 Flatfender Crawler/1991 Explorer Overlander/1991 Explorer Trail Truck

Last edited by Brian1; 12-09-2008 at 03:02 PM.
Reply With Quote
  #4  
Old 12-13-2006, 10:27 PM
Chassisguy's Avatar
Chassisguy Chassisguy is offline
Master Fabricator
 
Join Date: Jan 2006
Location: Jacksonville, NC
Posts: 179
That's way cool. Looks like a go-kart on steeriods. I like it
Reply With Quote
  #5  
Old 12-14-2006, 09:19 AM
KILLER"B"468's Avatar
KILLER"B"468 KILLER"B"468 is offline
Master Fabricator
 
Join Date: Mar 2006
Location: Hendersonville Tn.
Posts: 302
I use to take my kids up there to watch them... You were 5 miles from my house... when you were at the silverdome. The autoparts store got really busy on that saturday they even use to open for sunday just incase. I have welded a few parts and pressed a few parts for different teams in the past. Because the autoparts store couldn't. Cool project
Reply With Quote
  #6  
Old 12-14-2006, 12:14 PM
rocknbronco's Avatar
rocknbronco rocknbronco is offline
Master Fabricator
 
Join Date: Dec 2006
Location: Flat Top Mtn,Tn
Posts: 163
Quote:
Originally Posted by Chassisguy
That's way cool. Looks like a go-kart on steeriods. I like it
yeah they fly not for the faint of heart
Reply With Quote
  #7  
Old 12-09-2008, 01:20 AM
rickhz's Avatar
rickhz rickhz is offline
Junior Fabricator
 
Join Date: Dec 2008
Location: Phoenexico, Mexizona
Posts: 19
Hey Brian! I didn't know you were a mod here

What happened to your pics? They're not showing up for me.
Reply With Quote
  #8  
Old 12-09-2008, 02:06 AM
Duc's Avatar
Duc Duc is offline
Junior Fabricator
 
Join Date: Jun 2007
Posts: 4
Man Brian I wish I could also do the FSAE program at UNM but between full time work and class I dont think I will have time. I only get to watch them when I hit the machine shop next door.

Dam shame we can't hit up gonzo again since the tacoma has been updated again and soon to have 40's and allied beadlocks.
Reply With Quote
  #9  
Old 12-09-2008, 10:06 AM
Ladderbar's Avatar
Ladderbar Ladderbar is offline
Master Fabricator
 
Join Date: Apr 2007
Location: 6 burgh Go Steelers
Posts: 604
Sounds cool, but the pics didn't show up for me.
Reply With Quote
  #10  
Old 12-09-2008, 10:17 AM
Dqracer's Avatar
Dqracer Dqracer is offline
Master Fabricator
 
Join Date: Jun 2008
Location: Somerset KY.
Posts: 317
X2 here also ,,, no pics..
__________________
It ain't broke til' its hard to weld..

Dqracer
QuickEngineering.net
Reply With Quote
  #11  
Old 12-09-2008, 01:49 PM
Brian1's Avatar
Brian1 Brian1 is offline
Moderator
 
Join Date: Oct 2004
Location: Albuquerque, NM
Posts: 642
I will see if I can upload the pics again. On the older threads here on the board, something happened to the database and the attached pictures were lost.
__________________
Brian
1942 Flatfender Crawler/1991 Explorer Overlander/1991 Explorer Trail Truck
Reply With Quote
  #12  
Old 12-09-2008, 03:07 PM
Brian1's Avatar
Brian1 Brian1 is offline
Moderator
 
Join Date: Oct 2004
Location: Albuquerque, NM
Posts: 642
OK, pics have been reloaded although I couldnt find all of the ones I had posted previously.

Quote:
Originally Posted by rickhz View Post
Hey Brian! I didn't know you were a mod here

What happened to your pics? They're not showing up for me.
Hi Rick, welcome to the OFN!

Quote:
Originally Posted by Duc View Post
Man Brian I wish I could also do the FSAE program at UNM but between full time work and class I dont think I will have time. I only get to watch them when I hit the machine shop next door.

Dam shame we can't hit up gonzo again since the tacoma has been updated again and soon to have 40's and allied beadlocks.
It was alot of work, there were some days I spent 18 hours at school between classes and building the car.

40's! Nice! I miss gonzo canyon too, it was my favorite.
__________________
Brian
1942 Flatfender Crawler/1991 Explorer Overlander/1991 Explorer Trail Truck
Reply With Quote
  #13  
Old 12-09-2008, 03:21 PM
Duc's Avatar
Duc Duc is offline
Junior Fabricator
 
Join Date: Jun 2007
Posts: 4
Quote:
Originally Posted by Brian1 View Post

It was alot of work, there were some days I spent 18 hours at school between classes and building the car.

40's! Nice! I miss gonzo canyon too, it was my favorite.
Man that seems like a normal day between work and school or just working on the dam tacoma. I think I would be even heaven to be able to work on the race car but some dreams will just have to wait.

I did manage to get nights and weekend access to the student machine shop since I haven't found a good mill or lathe I want to buy locally lately.

Last edited by Duc; 12-09-2008 at 03:26 PM.
Reply With Quote
  #14  
Old 12-09-2008, 06:12 PM
Brian1's Avatar
Brian1 Brian1 is offline
Moderator
 
Join Date: Oct 2004
Location: Albuquerque, NM
Posts: 642
Quote:
Originally Posted by Duc View Post
I did manage to get nights and weekend access to the student machine shop since I haven't found a good mill or lathe I want to buy locally lately.
That was a nice perk. I made a couple of things for the Jeep on the mill there. Wish I still had access to the CNC!
__________________
Brian
1942 Flatfender Crawler/1991 Explorer Overlander/1991 Explorer Trail Truck
Reply With Quote
  #15  
Old 12-09-2008, 06:39 PM
Duc's Avatar
Duc Duc is offline
Junior Fabricator
 
Join Date: Jun 2007
Posts: 4
Quote:
Originally Posted by Brian1 View Post
That was a nice perk. I made a couple of things for the Jeep on the mill there. Wish I still had access to the CNC!
That may still be possible. I will see if I can get trained in on the CNC then we can use it also on the weekend. Maybe over the christmas break I can still work with him. I do know Tylor needs a adapter plate made up that we have a pdf file with all the dimensions.

The new shop teacher Dave seems to really know his shit. 20 plus years as a machinist in prototyping and used to own his own business. Actually he seems to care about helping people learn and understand how the machines work. He was willing to stay a hour over to help me tap my crawler box for a sight tube.
Reply With Quote
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -4. The time now is 06:54 PM.

Powered by vBulletin® Version 3.8.0
Copyright ©2000 - 2017, Jelsoft Enterprises Ltd.
Template-Modifications by TMS
Copyright 2012, Offroad Fabrication Network