Cutting Reminders

• Jig is being designed to act as a stencil to allow proper cutting of headlight (will be able to stand on its own)

• Undercutting is fine, not super problematic, can be sanded to perfection though tedious

• Overcutting is very problematic if headlight cutout is too big as filling in the gap can lead to aerodynamic flaws in aerobody

• Kerf needs to be considered when making design of headlight and cutting

• The space created by kerf can be used to help keep up the headlight for integration (originally thought of tape but requires re-consideration

Cutting Techniques

• Abrasive Waterjet supersonic erosion can cut through all composites (learned that there’s no hand held waterjet cutter so no waterjet)

• Laser cutting is an option as well but same problem as waterjet arises of portability

• For Carbon Fiber, the laser requires to be a CO2 or fiber laser

  • Best performance with hybrid laser of] 10.6 micron CO2 and 1.06 micron fiber wavelength mix

• Another problem with both laser and waterjet is that it is for 2D cutouts, same thing with CNC mill

Carbon Fiber

Rotary Techniques

• Dremel (Method of choice) with tungsten carbide or diamond bits (bits and blades are going to be checked to see what’s installed or available)

• Saws (jigsaw, bandsaw, scroll saw, table saw, etc.)

  • For jigsaw, it’s an option but creates a lot of dust which needs caution when handling. Vacuum can help control dust levels

  • Fine-tooth carbide blade would be used

• Abrasive cutting saws can be used as attachments

Hand Held Techniques

• Saws (Hacksaw, coping saw)

Increased TPI is better and thinner blade for sharper cuts

Angle Grinders

• Better than rotary but requires caution when using

• Abrasive cutting saw

https://www.elevatedmaterials.com/best-methods-for-cutting-carbon/

Kevlar

• Diamond wheel blade is optimal

• Tungsten carbide is an option but not as nice as diamond

• Kevlar is difficult to cut due to polymer chains

• Waterjet works on Kevlar but if there’s no hand held cutter we’re screwed!!

Dremel (more in-depth)

• Solid carbide or diamond grit for cutting composites

Integration

• Found out that integrating headlights is top secret and trade secret so no info on that

• Keep headlight up through attachment to aerobody itself

  • idea for bolting to chassis was put aside as chassis is too far away from aerobody especially at the back

• Headlight need to be flush with aerobody to maintain aerodynamics

• Some ideas we came up with in meeting:

  • Tacky tape around headlight to keep it in place and stop air to pocket or flow, less drag that way

  • Regular tape was used in MS14 to keep it up

• This ideas kind of got put aside for re-consideration as the light can heat up to very high temperatures (80 degrees) so the tape melting or deforming is highly possible making tape of any sort unfeasible

• More ideas are welcomed!!!!!!!!

Possible Ideas to Keep Headlights Sealed and Flush w/ Aerobody

Types of Headlight Sealants - for sealing the car lights (actual light structure); for preventing dim/foggy headlights [1]

• Polyurethane Sealant

  • Pros: air-tight seal, effective in preventing water and dirt from entering

  • Cons: can be expensive (depends ono brand), difficult to remove

• Silicone Sealant

  • Pros: flexible, does not crakc/peel, inexpensive

  • Cons: --

• Heat Resistant Headlight Sealant

  • Pros: good if the car gets very hot (or from the engine heat or the light bulb)
    -- won't crack or melt under high temp
    ^will probably be our best option based on the MS14 light temperatures (unless we find a way to maintain a lower temperature)

We can try to use multi-purpose silicone or gasket sealant to keep a flush seal with the aerobody:

• Multi-Purpose Silicone

  • Similar idea to how silicone is used to seal bathtubs in a washroom

  • Silicone Rubber Auto/Marine Sealant [3]

    • This type of silicone is used for automotive parts water/weatherproof

    • This product specifically is used for keeping a seal between lights and car body

      • Can assist with keeping an air-tight seal

• For Permatex Red High Temp Adhesive Sealant (gasket sealant) [2]

  • Withstand temps between -54 amd 343 degrees celsius

  • Waterproof, and resists cracking/shrinking/migration

  • Meant for other car parts, but it might serve the purpose of creating a seal (cheap to purchase)

Resealing Custom Headlights: How To RESEAL Custom Headlights

[1] Headlight Sealant Explored: Uses, Importance, and Recommendations - My Car Makes Noise
~:text=Polyurethane%20is%20a%20plastic%20material,from%20getting%20into%20your%20headlights.
[2] https://www.canadiantire.ca/en/pdp/permatex-red-high-temperature-rtv-gasket-maker-0383784p.html#:~:text=Temperature%20range%20%2D65%C2%BAF%20to%20650%C2%BAF,resists%20auto%20and%20shop%20fluids.
[3] https://www.dap.com/products-projects/product-categories/caulks-sealants/silicone/auto-marine-sealant/

Manufacturing

• Thermoforming of windshield is difficult (thinking of getting a company to do it for us for free just need to provide MDF and Mold)

• Jig will be 3D printed

• Thermoforming of headlight will be done in house just make sure to keep size small enough for it to fit in our machine

• Mold will be done with wood for head/tail light I believe (correct me if I’m wrong)

• Polycarbonate is used for windshield for REGS purposes