Door Design

Overview

Project team:
Project supervisor(s):	Jon Edward Gutierrez (Unlicensed), Kuldeep Panjwani (Unlicensed)
Stakeholders:
JIRA Link:

Vision

Background Information

The current door mounts on MSXI are not strong enough to hold the entire weight of the door when open. Additionally, the doors are very difficult to open.

Goal

Design a better mounting bracket for the door of MSXII so that it can be used properly.

Project Requirements

Rayce Regulations

These are requirements driven by the Rayce regulations.

Look through regulations for WSC/ASC and find out if anything might get in the way of the above goal.

Internal Requirements

These are requirements driven by Midnight Sun.

Must be able to support the weight of the door with no assistance
Must allow the door to swing open easily
Must be designed to optimize weight
Must allow doors to be operable from both inside and outside the car

Criteria

Specific strength, higher strength per unit weight is better
Manufacturing complexity, less time and lower complexity is better
Cost, lower is better (but still better to buy a slightly more expensive part over making it cheaply ourselves)

Designs

Come up with at least three designs and explain the advantages and disadvantages of each. Include sketches and screenshots of CAD models where applicable.

Design 1: Hidden Hinge.

Below is a CAD drawing of the hinge on the drivers side, since the door opens outwards (direction of the arrow). The black box will be welded to the chassis. I've also attached a pictures of a Hidden Hinge welded to the frame of the car as well as a dissembled hinge. The hinge is easily to install and to manufacture. It is also durable as the hinge extends out, holding the car's weight.

Buying Online/ Sourced Parts:

Speedy Motors: http://www.speedwaymotors.com/Universal-Hidden-Door-Hinges-1-Piece-Straight-Arm,37300.html

Include four hinges (2 pairs) made out of steel. Price: $324.99
American company situated in Nebraska
Ships to Canada, shipping cost around $25

Methods of Joining Door Hinge to Chassis:

	Advantage	Disadvantage
Welding	Provides strong joining Seamless bond Can be applied to all different geometric shaped objects	Permanent/ Prohibits disassembly when required Requires highly skilled labour to get a strong/ perfect bond
Roll Bar Clamp/ Clamping Screws	Allows for disassembly Easy to install Screws provide strength without damaging the integrity/ strength of the material	Possibility of adding weight to the car Excessive tightness of the clamp can cause damage
Gusset and Rivets	Easy to manufacture, cost and time efficient High resistance against vibrational loads	Riveting requires enough clearance when joining, compared to other methods Difficult to rivet cylindrical objects
Adhesive	Bonded joints are stiffer than spot welded joints Doesn't weaken the structure/ integrity of materials	Used on past MS car and was not proven to be successful Essentially permanent/ no disassembly Can be sensitive to temperature

Door Structure Material:

	Advantage	Disadvantage
Ex aluminum tube	Lightweight Easy to manufacture Still moderately strong	Needs to be professionally welded Interfacing difficult
Steel tubing	Strong Can weld ourselves	Heavy
Composite material	Lightweight	Can't really weld Not as strong as steel or aluminum

Door Handle Link: http://www.carparts.com/results/?Ntt=door+handles&searchType=global&N=&shopId=1&searchType=global&N=0

Door Dimensions:

Model	Width (in)	Height (in)
Honda Civic	44.09	40.16
Toyota Corolla	44.88	45.21
Toyota Prius	46.06	46.65
BMW 7-Series Sedan	41.1	39.6

Lexus RCF	55.5	38.2
Subaru BRZ	51.6	35.1
BMW i8	59.4	33.5