Floor Panel-Chassis Integration

Owned by Isha Warikoo
Last updated: Feb 03, 2021
2 min read

ASSEMBLY PLAN

General Notes

 

1. Dry-Run Clamping

  • Place the chassis upright, and lift the chassis using a platform to make it easier to access the tubes where the adhesive would be applied

    • Handle the chassis with care, to prevent scratching or chipping the powder coat when handling

  • Use C-clamps to secure the floor panels to the chassis' bottom reinforcement, seatbelt and A-plane tubes (as pictured, below)

  • Distribute weights as evenly as possible, along the medial sections of the panels (as pictured, below)

  • Add extra weights or clamps where necessary to close any gaps between the floor panels and chassis

    • Avoid over clamping as this can damage he carbon fibre panels and/or squeeze out any adhesive between the panel and chassis

  • Take pictures of the final set-up and areas where there may be any gaps between the panels and chassis, for reference

 

2. Surface Preparation

  • Sand off the powder coat and decarburization layer using the dremel and a sanding bit. The resulting surface should be silver and shiny (pictured below, reference image taken from the Bottom Panel-Chassis Integration Assembly Plan)

    • Wear safety glasses and KN95 masks while sanding

 

3. Application of Adhesive (Instructions below are referenced from the Bottom Panel-Chassis Integration Assembly Plan)

  • Wear gloves when handling chemicals and the epoxy adhesive

  • Clean the sanded surfaces of the chassis tubes using a cleaning product (stored
    on the top shelf of the chemical cabinet along with adhesives) and a damp paper
    towel. Then dry the surfaces completely.

  • Find 50 ml cartridges of LOCTITE EA E-120HP - Epoxy adhesive

  • The working time of the adhesive is 2 hours. Start a timer once mixing has
    started in the nozzle.

  • One person should apply adhesive to the chassis tubes using the applicator and
    at least one other person should spread it with a wooden mixing stick (found in a
    box beside the chemical cabinet). Add more adhesive as necessary until the
    surface is fully coated (see example below).

 

4. Clamping and Curing

  • Place the floor panels on the chassis and ensure it is aligned

    • Use the A-plane as a reference edge for the front two panels

    • Place the back two panels flush against the C-bulkheads

  • Replicate the final clamping assembly as from the dry-run

  • Fill any gaps between the panels and chassis tubes with adhesive, to ensure the adhesive is making contact with both components

  • Let the adhesive cure for 24 hours before removing the C-clamps and weights