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This document outlines the methods of manufacturing as well as the equipment needed for such methods.
Machining Plugs
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Part | MDF Sheet Dimensions (mm) | Order |
|---|
BatteryBoxWallPlug | 309.65 x 1170 x 20 (x3 sheets) | 1.5” x 4” x 20mm (x3 sheets) |
BatteryBoxBottomPlug | 795.66 x 1170 x 20 (x2 sheets) | 3” x 4” x 20mm (x2 sheets) |
BatteryBoxLidPlug | 808.36 x 1170 x 20 (x3 sheets) | 3” x 4” x 20mm (x3 sheets) |
RearElecLeftWallPlug | 309.65 x 1062.45 x 20 (x4 sheets) | 1.5” x 3.5” x 20mm (x4 sheets) |
RearElecRightWallPlug | 309.65 x 1062.45 x 20 (x4 sheets) | 1.5” x 3.5” x 20mm (x4 sheets) |
RearElecBottomPlug | 753.76 x 1001.66 x 20 (x2 sheets) | 2.5” x 3.5” x 20mm (x2 sheets) |
RearElecLidPlug | 798.36 x 1071.06 x 20 (x3 sheets) | 3” x 4” x 20mm (x3 sheets) |
Final Order | | 1.5” x 4” x 20mm (x11 sheets) 3” x 4” x 20mm (x10 sheets) |
CNC Prep Procedure
- Cut MDF to required size
- Glue sheets together
- Talk to Brian from E5 machine shop
Molds and Final Fibreglass Parts
Mold Manufacturing Plan
Final Fibreglass Part Manufacturing Plan
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Order of Manufacturing (First to Last) | Method |
|---|
BB Bottom | Wet Layup |
RE Bottom | Wet Layup |
BB Wall (x2) | Infusion |
BB Lid | Infusion |
RE Right Wall | Infusion |
RE Left Wall | Infusion |
RE Lid | Infusion |
Misc. Components Manufacturing Plan
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Securing Brackets
Refer to the Polycarbonate map for bracket cutouts.
Cut the brackets from the polycarbonate sheet (vertical band saw or waterjet, method TBD).
Label each bracket according to the diagram below.
There are 4 different bracket variations