Page Comparison

Summary of Bonding Methods

• Adhesives

  • Carbon fiber to flat steel tube/surface (bottom panel, bulkheads, floor panelbridges, bridges, trunk, doors)

  • Carbon fiber to perforated steel surface (side panel, trunk, roof , doorspanel)

  • carbon fiber to carbon fiber (bridges, hood, wheel cover)

  • Carbon fiber to polycarbonate (headlights, windows)

• Mechanical Fasteners

  • carbon fiber to polycarbonate (windshield)

  • carbon fiber to carbon fiber (wheel cover)

Joints to Test/Validate

• adhesives

  • edge of sandwich panel to CF surface (hood to BP joint)

  • Carbon fiber to perforated steel surface (side panel to bracket joints, roof panel to base stud joint)

• fasteners

  • bolt tear out in CF sandwich panel (wheel covers)

  • bolt tear out in polycarbonate (windshield)

Panel Specific Information

...

Panel	QTY	Fixed?	Substrate 1 (panel)	Substrate 2	Bonding Method	Details	Relevant Confluence Pages	Images	Testing Notes Suggestions
Bottom Panel	1	Y	Carbon fiber	Steel Tube (chassis)	adhesive	Directly bonded to chassis tubes (bottom, catamaran and trunk)	Bottom Panel-Chassis Integration Plan		test spacers for gaps between BP and chassis tubes
B-Bulkhead	2	Y	Carbon fiber	Steel Tube (chassis)	adhesive	Directly bonded to chassis tubes (B-pillar).	B-Bulkhead Assembly Plan	Image RemovedImage Added	double check inaccuracies in post-welded b-plane tubes
Floor Panels	4	Y	Carbon fiber	Steel Tube (chassis)	adhesive	Directly bonded to chassis tubes (bottom reinforcements).	Floor Panel-Chassis Integration		n/a
Bridges	6	Y	Carbon fiber	Steel Tube (chassis) Carbon fiber (side)	adhesive	Directly bonded to chassis tubes (round) OR side panel.	Bridges Integration Plan		n/a
Side Panels	2	Y	Carbon fiber	Steel Carbon fiber (chassisbridge) Steel brackets (bracketperforated)	adhesive	Top and bottom edges are bonded to the chassis. Middle sections are reinforced with 2 interlocking brackets: 1 adhered to panel, the other bolted to the chassis	SIDE PANEL(S)-CHASSIS INTEGRATION		test perforated bracket bonded to a curved panel
Roof	1	N	Carbon fiber	Steel? (perforate base stud)	adhesive (Hinge?)	Base stud adhered to inner surface of panel and secured through a welded tab on the chassis.	Roof Panel -- Aero-Chassis Integration		test perforated base stud bonded to a curved panel
Trunk	1	N	Carbon fiber	Steel? steel (hinge) ?	adhesive?	Hinge, latch and props	Trunk Hinges Trunk Latch
Doors	4	N	Carbon fiber	Metal bracket steel (hinge) ?	adhesive	Panel glued to a bracket which is fastened to hinge. The hinge is bolted to chassis.
Hood	1	Y	Carbon fiber	Carbon fiber (side, bottom panels)	TBD - most likely adhesive	May require reinforcement along bottom edgeBonding areas along side panel and bottom panel.	Hood + Windshield Panel Fastening MethodsIntegration Project		watch sealing of hood and BP
Wheel Covers	4	?N	Carbon fiber	Carbon fiber (side panel)	TBD	adhesives if fixed, fasteners if removable	Image Removed	Fasteners (Bolt)	Adhesive mount nut on inside face of side panel flange. Bolt through wheel cover and side panel.	Wheel Cover Integration - Development	Image Added	test for bolt tear out (in addition to hand calcs)
Windows	4	Y	Polycarbonate	Carbon fiber (doors)	adhesive	PC panel adhered to CF flanges	Window Panel Integration Plan		test thermoformed panel material (polycarbonate?) and selected epoxy adhesive
Windshield	1	N	Polycarbonate	Carbon fiber (bridge, hood, sides)	TBD Quarter-turn fasteners	Holes need to be drilled along borders	Hood + Windshield Panel Fastening MethodsIntegration Project Windshield Fastening		test for bolt tear out (in addition to hand calcs)
Headlights	2	Y	Polycarbonate	Carbon fiber (hood, sides)	adhesive	PC panel adhered to CF flanges	Lights DFMA		test thermoformed panel material (polycarbonate?) and selected epoxy adhesive