Panel Fastening/Bonding Details

Summary of Bonding Methods

Adhesives
- Carbon fiber to flat steel tube/surface (bottom panel, bulkheads, bridges, trunk, doors)
- Carbon fiber to perforated steel surface (side panel, roof panel)
- carbon fiber to carbon fiber (bridges, hood)
- Carbon fiber to polycarbonate (headlights, windows)
Mechanical Fasteners
- carbon fiber to polycarbonate (windshield)
- carbon fiber to carbon fiber (wheel cover)

Joints to Test/Validate

adhesives
- edge of sandwich panel to CF surface (hood to BP joint)
- Carbon fiber to perforated steel surface (side panel to bracket joints, roof panel to base stud joint)
fasteners
- bolt tear out in CF sandwich panel (wheel covers)
- bolt tear out in polycarbonate (windshield)

Panel Specific Information

Panel	QTY	Fixed?	Substrate 1 (panel)	Substrate 2	Bonding Method	Details	Relevant Confluence Pages	Images	Testing Notes Suggestions

Panel	QTY	Fixed?	Substrate 1 (panel)	Substrate 2	Bonding Method	Details	Relevant Confluence Pages	Testing Notes Suggestions
Bottom Panel	1	Y	Carbon fiber	Steel Tube (chassis)	adhesive	Directly bonded to chassis tubes (bottom, catamaran and trunk)	Bottom Panel-Chassis Integration	test spacers for gaps between BP and chassis tubes
B-Bulkhead	2	Y	Carbon fiber	Steel Tube (chassis)	adhesive	Directly bonded to chassis tubes (B-pillar).	B-Bulkhead Assembly Plan	double check inaccuracies in post-welded b-plane tubes
Floor Panels	4	Y	Carbon fiber	Steel Tube (chassis)	adhesive	Directly bonded to chassis tubes (bottom reinforcements).	Floor Panel-Chassis Integration	n/a
Bridges	6	Y	Carbon fiber	Steel Tube (chassis) Carbon fiber (side)	adhesive	Directly bonded to chassis tubes (round) OR side panel.	Bridges Integration Plan	n/a
Side Panels	2	Y	Carbon fiber	Carbon fiber (bridge) Steel brackets (perforated)	adhesive	Top and bottom edges are bonded to the chassis. Middle sections are reinforced with 2 interlocking brackets: 1 adhered to panel, the other bolted to the chassis	SIDE PANEL(S)-CHASSIS INTEGRATION	test perforated bracket bonded to a curved panel
Roof	1	N	Carbon fiber	Steel (perforate base stud)	adhesive (Hinge?)	Base stud adhered to inner surface of panel and secured through a welded tab on the chassis.	Roof Panel -- Aero-Chassis Integration	test perforated base stud bonded to a curved panel
Trunk	1	N	Carbon fiber	steel (hinge) ?	adhesive	Hinge, latch and props	Trunk Hinges See "Trunk Latch Project 2.0 (Current - S21)" for current project info
Doors	4	N	Carbon fiber	steel (hinge) ?	adhesive	Panel glued to a bracket which is fastened to hinge. The hinge is bolted to chassis.
Hood	1	Y	Carbon fiber	Carbon fiber (side, bottom panels)	adhesive	Bonding areas along side panel and bottom panel.	Hood + Windshield Panel Integration Project	watch sealing of hood and BP
Wheel Covers	4	N	Carbon fiber	Carbon fiber (side panel)	Fasteners (Bolt)	Adhesive mount nut on inside face of side panel flange. Bolt through wheel cover and side panel.	Wheel Cover Integration - Development	test for bolt tear out (in addition to hand calcs)
Windows	4	Y	Polycarbonate	Carbon fiber (doors)	adhesive	PC panel adhered to CF flanges	Window Panel Integration Plan	test thermoformed panel material (polycarbonate?) and selected epoxy adhesive
Windshield	1	N	Polycarbonate	Carbon fiber (bridge, hood, sides)	Quarter-turn fasteners	Holes need to be drilled along borders	Hood + Windshield Panel Integration Project Windshield Fastening	test for bolt tear out (in addition to hand calcs)
Headlights	2	Y	Polycarbonate	Carbon fiber (hood, sides)	adhesive	PC panel adhered to CF flanges	Lights DFMA	test thermoformed panel material (polycarbonate?) and selected epoxy adhesive