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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

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

Calculation Assumptions:

  • Entire mass of vehicle is considered in the 2G bump force

  • Assuming worst case condition, where the entire load is applied in shear

  • Max. shear strength of LOCTITE® EA E-120HP adhesive = 20 N/mm^2 (is assumed to be equivalent to that of the adhesive being cured on Epoxy material for 12 hours @ 65 °C)

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

Bonding to Adjacent Panels

Method

Validation/Rationale

Side panels

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

Final Design

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Research

Magnets

This option is ideal for holding panels with unusual geometry in place during the adhesive curing process

1. Eastwood magnets to hold panels (https://www.amazon.com/Eastwood-Stitch-Magnets-Construction-Panels/dp/B016UV3I2O)

2. Epoxy coated disc magnets (https://www.amazon.ca/Neodymium-Countersunk-Magnets-Permanent-Magnets/dp/B07TRHT5WB/ref=sr_1_14?dchild=1&keywords=pair+of+strong+magnets&qid=1617213443&sr=8-14)

  • Magnets can support a 12kg pull force

3. Brushed nickel hook magnets (https://www.amazon.ca/Lictin-Magnetic-Hooks-6pcs-Magnets-Diameter/dp/B07QDSQHRT/ref=sr_1_2?dchild=1&keywords=magnets+to+hold+metal+panels&qid=1617211910&sr=8-2)

Manufacturing and Assembly Plans

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