SIDE PANEL(S)-CHASSIS INTEGRATION

Research and Concept Development

  1. The first method outlined uses adhesive base studs and brackets to integrate the panel to the chassis. A sample solution is posted below.

    1. Design details: Brackets are welded or bolted to chassis tubes. Base studs are attached with epoxy. Base studs are then screwed placed into bracket slot and a nut is attached to the threads securing the panel to the chassis.

    2. Pros/Cons:

      1. Pros:

        1. Same method used on previous car

        2. simple construction

      2. Cons:

        1. Requires more accurate placement onto panel, the curvature of the panel could slant the stud misaligning the threads with the hole/slot.

        2. Requires a unique bracket for each mounting location because curvature is different at each panel

           

  2. The second method uses an eye bolt, and a ring to integrate the panel with the chassis. A sample solution is posted below.

    1. Design details: The platform of the ring is fixed to the panel using epoxy, and the shank of the bolt is fed and tightened through a hole in the chassis.

    2. Pros/Cons:

      1. Pros: Allows for virtually any part of the side panel to be mounted, the ring will pivot and rotate as needed to fit the curvature of the panel.

      2. Cons: Without top and bottom adhesion could shift around (unless the rings were alternating in orientation to account for that.

  1. Just a bracket bolted to the chassis and fixed to the panel using epoxy.

  • Pros:

    • 1 piece (with exception of mounting bolts)

  • Cons:

    • Heavy (if machined out of aluminum or steel)

    • Unique brackets for each mounting spot

    • Potential for gaps due to flat bracket surfaces and a curved panels

  1. Aircraft cable to wire fed through rings on the panels and chassis to secure the panel. Can be woven or one rope segment per loop.

  • Pros:

    • Super light

    • Extremely flexible

    • Can pull from any direction

  • Cons:

    • Any slack provides no support

  1. Hinge bolted to chassis and fixed to panel using epoxy

  • Pros:

    •  

  • Cons:

Calculations and Analysis

 

https://docs.google.com/spreadsheets/d/1gKbABiWBjY50Pu3EAMfISt4W0gQMfHPN60STEE0tBwI/edit?usp=sharing

Final Design

 

Final Design Summarized Steps:

  1. Manufacture Chassis and Panel Brackets

  2. Prepare all required surfaces for adhesive application

  3. Bolt chassis brackets to chassis

  4. Do a dry run and outline where the panel brackets will be adhered

  5. Adhere the panel to the panel brackets, as well as the top bridge and bottom chassis tubes

Manufacturing and Assembly Plans