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Isha Warikoo

Yanshen Zhou

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*Bonding areas to be verified

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DRI

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Reviewers

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Isha Warikoo

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Kimberly Liu

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

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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/

Research and Concept Development

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Windshield Panel

The fastening methods alternatives for the windshield are aimed to be removable, efficient installation, and cost-effective.

Surrounding panels: Roof panel, hood, side panel (driver’s side and passenger side) and bulkheads?

Also see: Windshield Fastening

Captive Panel Screw

  1. Quarter-Turn Capacitive Panel Screw

  • Rivet-mount nut and Quarter turn screw

  • Zinc-plated steel and corrosion resistant

  • Cost: ~$3/each

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https://www.mcmaster.com/quarter-turn-fasteners/rounded-head-quarter-turn-captive-panel-screws-with-rivet-mount-nut/

https://www.mcmaster.com/quarter-turn-fasteners/rounded-head-quarter-turn-captive-panel-screws-with-clip-on-nut/ → Applicable to larger panel thickness range

(Quarter-Turn Fastener in-use is similar to: https://www.youtube.com/watch?v=EnNuQW5P9cs @15:18 min)

Sizing for Dzus Fasteners:

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(Image link: https://static.speedwaymotors.com/images/charts/Measuring_Guide.jpg)

Fastening hood + windshield for example, has a combined thickness of 12 mm = 0.47 inches, thus a dzus fastener with 0.6 inch + button length would be appropriate

Quarter-turn fasteners: https://www.speedwaymotors.com/Steel-Oval-Head-Quarter-Turn-Fasteners-600-Inch-Grip-Pack-10,29397.html

0.700 inch grip Dzus fasteners: https://www.speedwaymotors.com/Self-Ejecting-Quarter-Turn-Fasteners-700-Inch-Grip-Pack-10,29647.html

https://timmcamis.com/shop/chassis/dzus-fasteners.html

  1. Twist-to-Lock Press-Fit Capacitive Panel

  • Pull knob and rotate 90 degrees to lock

  • Zinc-plated steel and corrosion resistant

  • Cost: ~5.42/each

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https://www.mcmaster.com/quarter-turn-fasteners/twist-to-lock-press-fit-captive-panel-retractable-spring-plungers/

Quick-Release Pins

  • Zinc-plated, mild corrosion resistance and Flat-head

  • Sizes diameter: 3/16”, 1/4”, 5/16”, 3/8”, 1/2”

  • Cost: ~$10 / 10 pieces

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https://www.mcmaster.com/pins/flat-head-quick-release-pins/

https://www.mcmaster.com/pins/add-a-handle-quick-release-pins/

Rivet Nut + Screw

Steel Twist Rivet Nut: https://www.mcmaster.com/rivet-nuts/steel-twist-resistant-rivet-nuts/

  • Thread size: 1/2”-13, body diameter: 0.685”, body length: 1.450”

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Flat-head screw: https://www.mcmaster.com/screws/flat-head-screws/vibration-resistant-flat-head-screws/

  • Thread size: 1/2”-13, length: 1.25”

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Calculations

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titleRequirements for fastener:

Front Bridge Panel thickness: 6.5 mm

Windshield thickness: 6.35 mm

Hood flange thickness: 6 mm

Front bridge & windshield combined thickness: 12.5 mm = 0.49 inches

Hood flange & windshield combined thickness: 12 mm = 0.47 inches

Side Panel: 1/4”

Dzus Fastener grip length = combined panel thickness + spring height (ranges from 0.15” to 0.175”)

Max grip length required = 0.49” + 0.175” = 0.665”

Min grip length required = 0.47” + 0.15” = 0.62”

Final Design

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Windshield Mounting Methods & Locations

Verification/Rationale for Final Design

Portability

Profile (Shape)

Effectiveness

Cost

Quarter Turn Fasteners

Very quick to attach/remove (a screw that disengages in a quarter turn)

Screw does not stick out and certain screw-heads can sit flush with the windshield surface

Windshield is attached securely and does not budge

~$3-5.42 Each

Quick-Release Pins

Quickest to Attach (just a pushing motion); Detaching requires more time than quarter turn fastener

Pin sticks out more than the quarter turn fastener

Windshield may wobble

~$1 Each

Rivet Nut + Screw

Mechanism similar to quarter turn screw, except attaching/detaching Rivet Screw takes significantly more time

Not as large as Quick Release pins but end of screw may protrude out more than quarter turn fasteners

Most effective, as the threads of the screw prevent any movement of the windshield

~$1 Each

As the Quarter Turn Fasteners excel in portability and do not have any significant downsides, they are the most effective solution for windshield panel mounting.

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

Bonding to Adjacent Panels

Method

Hood

Quarter-turn fasteners

Side Panels

Quarter-turn fasteners

Front Bridge

Quarter-turn fasteners

Windshield to Hood

Quarter-turn fasteners would be used to fix the windshield to the hood. These fasteners would be mounted along the flange of the hood panel (Figure 1, below). It is suggested that 6 screws be used to support mounting of the windshield to the hood.

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Figure 1: Quarter-Turn Fasteners on the Hood

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Figure 2: Measuring Guide for Dzus Quarter-turn Fasteners

Length C, grip length = 0.7 inches and diameter of the screw is 5/16 inches (link: https://www.speedwaymotors.com/Self-Ejecting-Quarter-Turn-Fasteners-700-Inch-Grip-Pack-10,29647.html)

Windshield to Front Bridge

Quarter-turn fasteners would be used to fix the windshield to the front bridge. These fasteners would be mounted as pictured (Figure 3, below). It is suggested that 6 screws be used to support mounting of the windshield to the front bridge.

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Figure 3: Quarter-turn Fasteners on the Front Bridge

Windshield to Side Panel

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Keeping the trend of using 6 fasteners, the fasteners will be spread out evenly across 1158.98 mm.

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Therefore, the Quarter-turn Fasteners will be mounted onto the side panel as such:

(Note: the configuration of fasteners is the same on both side panels)

Manufacturing and Assembly Plans

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Materials:

  1. 25 x Quarter Turn Fasteners (specific brand and model to be determine)

  2. Windshield Panel

  3. Hood Panel

  4. Front Bridge

  5. Side Panel

  6. Drill

  7. Screwdriver

Instructions:

  1. Drill holes marked in correct positions for hood panel, front bridge, and side panels.

  2. Line up windshield with the panels above, then mark hole positions to be drilled on windshield

  3. Drill holes in windshield

  4. Screw in fastener panels into the hood panel, front bridge, and side panels

  5. Attach the windshield onto the panels

  6. Insert the buttons into all the holes on the windshield

Info

Quarter Turn Fasteners consist of two parts - the panel and the button. The panel will be secured onto a surface and the button then locks into the panel.