March 31, 2021 Update:

Sample Manufacturing Procedure:

A sample manufacturing procedure is laid out for mount manufacturing, mount fastening, and fastener to roof mounting. This procedure follows an estimated time that may change as we go.

1. Cutting The Mounts ( 3 - 4 hrs )

   1. Total of 6 mounts are cut in the machine shop using either a waterjet or plasma cutter

   2. Mount angles are grinded off using a low grit angle grinder wheel

   3. Remove sharp edges using a file/rasp

2. Setting up Jigs for Mount Welding ( 3 - 4 hrs )

   1. Jigs are to be set up by hand in the bay

   2. Detail-oriented process, ensuring mounts are level and held in place

3. Welding the Mounts to Chassis ( 1 day lead time, not much manual labour )

   1. Chassis along with the jigged mounts is sent to the welding shop for welding

   2. Not much to be done manually here, just waiting for the welding shop to get back

4. Setting up Roof Panel Fasteners ( 4 - 5 hrs )

   1. Spacers are added to the 6 base studs needed

   2. Positioning guides are set in the stud mounting location

   3. Adhesive is applied to the mounting locations

   4. Base studs/nuts are clapped into position ensuring an even spread of adhesive

5. Removing jigs and mount guides( 1 - 2 hrs )

   1. Remove jigs and positioning guides

   2. Ensure an even weld/adhesive has been applied

   3. If more adhesive/weld is needed, add some

Sample Jig Manufacturing Procedure:

Most of the roof fastener positioning guides can be 3D-printed or roughly cut from any remaining sheet metal. The welding jigs for the chassis mounts might need to be machined to prevent any heat from melting them. The one issue that comes about with machining the jigs is that they can’t be bulk produced.

1. Jig and Fastener Positioning Guide Manufacturing (12 - 15 hrs, depending on manufacturing method)

   1. 6 Mounts and 6 positioning guides are needed to be manufactured

   2. 3D printing and machining can be done in house