Compiling notes, tips, and instructions on various stages of Aero-Chassis Integration

W21 - Aero-Chassis Integration Resources

Adhesives Information:

Adhesive Usage: LOCTITE EA E-120HP - Epoxy adhesive - Henkel Adhesives (henkel-adhesives.com)

In the bay:

F2020 - ordered 10 x 50 mL cartridges

General Advice:

Panel Integration Plans [WORK IN PROGRESS]:

Integration Timeline and Instructions

• A, C Bulkheads
• Bottom Panel Bottom Panel-Chassis Integration Plan

[ Dynamics Assembly / Panel Manufacturing ]

• B-Bulkhead B-Bulkhead Assembly Plan

[ Panel Trimming (see below) & Painting / Interiors Assembly ]

• Floor Panels Floor Panel-Chassis Integration
• Bridges
• Side Panels SIDE PANEL(S)-CHASSIS INTEGRATION
• Hood
• Roof (removable)
• Trunk (removable)

[ Thermoformed Panels Complete ]

• Doors + Windows
• Windshield (removable)
• Headlights Lights DFMA

Panel Specific Information

The following page summarizes all the aerobody panels and their respective fastening/bonding methods.

Panel Fastening/Bonding Details

Panel Trimming Order

1. Bottom Panel - trimmed using mold outline

2. Bulkheads - trimmed using a stencil

3. Bridges - trimmed using mold outline

4. Side Panels - trimmed using mold outline, clamp to chassis, trim to fit with bottom panel, bridges

5. Trunk - trimmed using mold outline, clamp to chassis, trim to fit with bottom panel, side panel, bridges

6. Roof - trimmed using mold outline, clamp to chassis, trim to fit with side panels, bridges

7. Hood - trimmed using mold outline, clamp to side panels and trim to bottom and side panels

8. Doors - trimmed using mold outline, trim to side panels

9. Floor panels - trimmed using a stencil (?), trim to fit within chassis, bulkheads and seats