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DRI

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Reviewers

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Isha Warikoo

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Kimberly Liu

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Research and Concept Development

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Hood Panel

The fastening method alternatives for the hood panel are aimed to be permanent, efficient installation, and cost-effective.

Surrounding panels: Side panel (driver’s side and passenger side), headlights, bottom panel and bulkheads?

Epoxy Adhesive

  • Applied to fix it to the side panels and bulkheads

Flush-Mount Blind Rivets

  1. Flush-Mount Rivet

  • Aluminum and corrosion-resistant

  • Sizes diameter (Thickness of material): 3/32” (0.062”-0.125”), 1/8” (0.092”-0.625”), 5/32” (0.062”-0.5”), 3/16” (0.188”-1”), 1/4” (0.188”-0.375”)

  • Cost: ~$9.40 / 100 pieces

Image Added

https://www.mcmaster.com/rivets/aluminum-flush-mount-blind-rivets/

  1. Flush-Mount on both sides Blind Rivet

  • Zinc-plated, and mild corrosion resistance

  • Sizes diameter (thickness of material): 1/8” (0.059”-0.177”)

  • Cost: ~$10 / 50 pieces

https://www.mcmaster.com/rivets/flush-mount-on-both-sides-blind-rivets/

Calculations

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1.1 Hood Mounting Methods & Locations

Table 1: Proposed Mounting Locations & Method for the Hood Panel

Bonding to Adjacent Panels

Method

Validation/Rationale

Headlights

Epoxy Adhesive

Bonding area calculations (Excel attached, below)

Windshield

Quarter-turn fasteners

Windshield must be removeable, quarter-turn fasteners will be used for windshield mounting to other panels

Bottom Panels

Epoxy Adhesive

Modify hood panel to have inward curve along the bottom edge to allow the panel to join with the bottom panel.

Hood-headlight bonding area validation:

View file
nameHood-bonding-hand-calcs.xlsx

1.2 Windshield Mounting Methods & Locations

Table 2: Proposed Mounting Locations & Method for the Windshield Panel

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Bonding to Adjacent Panels

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Method

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Validation/Rationale (In progress)

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Hood

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Quarter-turn fasteners

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Windshield must be easy to remove

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Side Panels

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Quarter-turn fasteners

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Windshield must be easy to remove

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Front Bridge

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Quarter-turn fasteners

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Final Design

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Manufacturing and Assembly Plans

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