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Foam/MDF Dimensions
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Part | MDF Sheet Absolute Dimensions (mmin) | Order (in) |
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BatteryBoxWallPlugBatteryBoxWallMold | 30912.65 x 1170 x 20 (x3 sheets) | 1.5” x 4” x 20mm (x3 sheets) | BatteryBoxBottomPlug | 795.66 x 1170 x 20 (x2 sheets) | 3” x 4” x 20mm 19 x 46.06 x 2.36 | 14 x 48 x 2 (x2 sheets) | BatteryBoxLidPlugBatteryBoxLidMold | 80832.36 55 x 1170 x 20 (x3 sheets)3” x 4” x 20mm (x3 46.06 x 2.78 | 34 x 48 x 2 (x2 sheets) | RearElecLeftWallPlugRearElecLeftWallMold | 30912.65 19 x 106241.45 x 20 (x4 sheets)1.5” x 3.5” x 20mm (x4 83 x 3.03 | 14 x 48 x 2 (x2 sheets) | RearElecRightWallPlugRearElecRightWallMold | 30912.65 19 x 106241.45 x 20 (x4 sheets)1.5” x 3.5” x 20mm (x4 83 x 3.03 | 14 x 48 x 2 (x2 sheets) | RearElecBottomPlugRearElecLidMold | 75332.76 63 x 100142.66 x 20 (x2 sheets)84 x 2.5” x 3.5” x 20mm 59 | 34 x 48 x 2 (x2 sheets) | RearElecLidPlug | 798.36 x 1071.06 x 20 Final Order | | 48 x 96 x 2 (x3 sheets) | 3” x 4” x 20mm (x3 sheets) | Final Order | 1.5” x 4” x 20mm (x11 sheets) 3” x 4” x 20mm (x10 sheets) |
CNC Prep Procedure - Cut MDF to required size
- Glue sheets together
- Talk to Brian from E5 machine shop
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Molds and Final Fibreglass Parts
Mold Manufacturing Plan
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Final Fibreglass Part Manufacturing Plan
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Order of Manufacturing (First to Last)
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Method
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BB Bottom
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Wet Layup
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RE Bottom
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Wet Layup
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BB Wall (x2)
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Infusion
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BB Lid
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Infusion
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RE Right Wall
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Infusion
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RE Left Wall
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Infusion
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RE Lid
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Infusion
Misc. Components Manufacturing Plan
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Securing Brackets Refer to the Polycarbonate map for bracket cutouts. Cut the brackets from the polycarbonate sheet (vertical band saw or waterjet, method TBD). Label each bracket according to the diagram below. There are 4 different bracket variations
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+ 3 sheets extra = 6 sheets (Foam) 48 x 96 x 3/4 (x8 sheets) + 3 sheets extra = 11 sheets (MDF) |
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