Page Comparison

Catamaran Cover + Seats

Obtain all materials required for manufacturing the catamaran cover
(MDF, layup consumables)

Finish assembly plan

BOT

All MDF for catamaran cover by mid-march, mdf for seats and doors by EOT

Catamaran Cover

Manufacture Molds

• Cut and glue MDF

• Machine molds

• Sand and prime

2 weeks

Manufacture Major Battery Box Panels (bottom + side walls + lid)

• Prep work

• Make extra for test specimens

3 weeks

Manufacture Internal Parts
• 3D printing
• Cutting and thermoforming polycarbonate

1 week

Material Testing

• Deflection test

• Heat test

• Adhesive test

1 week

Dry Run Assembly with Electronics

• Install electronics and battery modules

• Mark part locations

• Test fit catamaran cover into car

→ Will gate electrical

1 week

• will require coordination of finished chassis, bottom panel, battery modules

Final Assembly
• Epoxy internal components
• Install electricals

• Permanent mounting of catamaran cover to chassis

2 weeks

External Finish
• Add fabrics and other cosmetic trim to battery box

TBD

Seats

Seats Mock-up (optional)
• Fabricate and install flat panels in wood to verify seating position, harness pass-thru, visibility, steering wheel and pedal position
• May need to mock-up seatback using flat sheets

1 week

Manufacture Seats Flat Panels using the Glass panel

• Fabricate all seat pan & seat support flat panels in carbon fibre (either in 1 go or 2 depending on the size of vacuum bag)

• Bond flat panels to bottom panel/structural elements

2 weeks

Manufacture seat supports

• depending on method chosen:

  • 2 built in filets (require small amount of mdf and require producing each seat support separately which is time consuming considering there are 8 of them)

  • 1 built in filet (require producing each seat support separately which is time consuming considering there are 8 of them)

  • 0 built in filets (will be weaker around 1.5-3 times based on research but can manufacture flat pieces 4 supports at a time meaning there will only be 2

• • rounds of infusion)

2 filets 3 weeks

1 filet 2-3 weeks

0 filets 1 week

Ballast using using the Glass panel

• after install of seat pan the measurements and checking to make sure the ballast will hold enough weight/there will enough room

• begin manufacturing flat panels (glass sheet)

• install with hinges, lock, and lid

2 weeks

Brackets and fastener installation

• order brackets (if VDR approved)

• order screwsbigheads

• order fuji/flex locks

• drill appropriate holes and weld brackets onto chassis

3 weeks

• Further purchases are required (brackets approved by EngSoc)

• fasteners TBD

Manufacture Seatbacks
• Fabricate tooling for non-flat panels (mdf)
• Fabricate non-flat seatback panels
• Install seatbacks into car (as well as seat tabs)

2 weeks + 1 week = 3 weeks

Finishing Touches
• Fabricate foam padding and cushions and install
• Fabricate and install remaining fabric coverings
• Install harnesses

TBD

• These can be done over long term

• Further purchases are required: fabric