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Hood PanelThe 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
Flush-Mount Blind Rivets
 https://www.mcmaster.com/rivets/aluminum-flush-mount-blind-rivets/
https://www.mcmaster.com/rivets/flush-mount-on-both-sides-blind-rivets/ |
Calculations
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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
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Bonding to Adjacent Panels
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Method
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Validation/Rationale
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Side panels
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Epoxy Adhesive
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Bonding area calculations (Excel attached, below)
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Windshield
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Quarter-turn fasteners
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Windshield must be removeable, quarter-turn fasteners will be used for windshield mounting to other panels
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Bottom Panels
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Epoxy Adhesive
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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:
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Final Design
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ResearchMagnets This option is ideal for holding panels with unusual geometry in place during the adhesive curing process1.
https://www.amazon.com/Eastwood-Stitch-Magnets-Construction-Panels/dp/B016UV3I2O)2.
https://stronghandtools.com/stronghandtools/products/other-magnetic-products/sheet-metal-magnets/) |
Calculations
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Hood Mounting Methods & LocationsCalculation Assumptions:
Table 1: Proposed Mounting Locations & Method for the Hood Panel
Hood-headlight bonding area validation: 
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Final Design
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Hood to Side PanelsThere are two flanges on the side panels (Figure 1, below) that would be the mounting locations to the hood panel. Epoxy adhesive would be applied to the mounting locations, and the flange clamped to the hood with a c-clamp or spring clamp (Figure 2, below).  Figure 1: Side panel flange, mounting location  Figure 2: Spring Clamp Hood to Bottom PanelThe hood and bottom panel have an interfacing bottom edge, where adhesive can be applied. Additionally, adhesive tape can be applied to seal these panels together.
Hood to WindshieldQuarter-turn fasteners would be used to fix the hood to the windshield. These fasteners would be mounted along the flange of the hood panel (additional details are included in the windshield document). |
Manufacturing and Assembly Plans
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