Ribs/ Bulkheads

Purpose

Ribs are used to provide extra rigidity to the aerobody panels and the means of how the aerobody panels are being mounted to the chassis.

W2023 - Added purpose of supporting the roof

Layout

*Contemplating the number of ribs towards the side of the car (2/3)

Manufacturing

Material: The ribs will be comprised of 1/4” thick foam core sandwiched between two layups of carbon fiber (if ribs are required to be structural for the mounting points for other features in the car, the foam core will be up to an 1” thick).

Layup: The ribs will manufactured through the method of wet layup on a flat surface then cut to shape.

Mounting to Chassis

Locating: Each rib has a hook cut out that would allow for easier location and placement into each of the ribs respective locations, additionally there are cut outs to allow for the clearance of the tubes of the bottom profile of chassis. *Due to tub mold, hooks would point upwards - opposite to image*

Joining to Chassis:

Nose Ribs: Custom part to be tangent to the chassis tube, than parallel to rib face

• Alternative: Add a tube to the front-most plane of chassis, so joining is the same as tail rib

Side Ribs: Rib is to be tangent to two tubes and a pipe clamp will be used

Tail Ribs: Bolted connected through clearance holes into the ribs and chassis tubes

• Fastener Setup: 1.75” bolt, washer, Rib, washer, chassis tube, nut

  • The washers sandwiching the rib will distribute the compressive stress caused from tightening the bolt and pressing tangent against the chassis tube.

Bonding to Aerobody

• Process: 1) Trim rib to match the inner curvature of the aerobody (using Dremel) 2) Resin applied to the trimmed edge 3) Use Kevlar tape along the front and back side of the rib, essentially making a T-Joint with the aerobody.

• Main Concern: Alignment to Aero, needs to be perpendicular to the chassis and aerobody

Alignment Method (For Tub Mold)