Mech-Onsite Updates

October 31 2020

Shi Jing Yang and Min Qian Lu

Mold release test layup

Prepreg is coming out a big sketchy (bendy in some small areas of the edges/corners). Could be due to improper cure cycle. Will look into it

Mold release also applied and cured far below recommended temp (cured at 0 Celsius)

October 31 2020

Isabella Shcneider, Michael Hanley, Colby Wang, SJ, Min

Mold release applied to big glass panel

spotty application?

Nov 1 2020

Michael Hanley, Johnson Duong, Isabella Schneider, Joy He and Min

Front Bulkhead layup

Vacuum bag was not held for the full 8 hour cure

Nov 2 2020

Winnie Lin and Min

Vacuum bag failure investigation + tiny bit of F.bulkhead release

How to deal with tape not adhering to mold release? Apply mold release to other side? or sand current side

Nov 3 2020

Colby Wang

Cut breather cloth

To clean working area

Nov 3 2020

Isabella, Brielle, XP, Min

Pick up and cut carbon fiber, disassembled oven for space

might not have enough CF for 45 deg offset rear bulkhead legs - another conestoga run? Puzzle piece scraps?

Nov 3 2020

Kimberly Liu

Connected left and right side of overall chassis jig. Added clamps for securing bottom panel tubes.
Cut adhesive film for rear bulkhead layup

May need to move the chassis jig so it doesn’t block access to the tools area.

Nov 3 2020

Micah Black

Bent current collectors for battery box
Started installing heat set inserts in the

Nov 4 2020

Micah Black, Michael Hanley, XP, Min

Moved MSXII chassis to E3 for scrap
Filled E5 dumpster with MSXII’s carbon parts (had to cut up bottom panel to make it fit)
Moved some extra MDF out of the composites room
MSXII seats, lights, motors, wheel, and dynamics/steering parts stored in the bay

Need more particulate filters for respirators (P100 and fits on the respirators - apparently we have 2 or 3 different styles of cartridge adapters)

Also still need to disassemble the steel cage for the bottom panel that we made earlier.

Nov 5 2020

Kaveet, Isabella, Filip, Min

Remove front bulkhead, tape off and apply mold release to other side of glass

goals + peel ply was cut by Filip

• F.Bulkhead came off in 20 mins.

Everything is ready to go for Layup, tomorrow will be a last check

Chassis:

• Chassis has been rotated for more space in the bay.

• A-plane reference

Nov 6 2020

• Last verification for layup prep (Layup will be happening Sat. or Sun.)

• XP picking up prepreg from Conestoga

• Get Bay back online

• Chassis - securing C-Pillar

• Brake Pedal Face trimming

• Check for paint primer in the bay (for Chassis coating)

• Linamar Filming

• C-pillar and bottom panel tubes added to jig

• we have lots of paint/primer in the cabinets

Nov 7 2020

Aero

• Layup prep - completed

Chassis

Nov 8 2020

Aero

• Rear bulkhead layup was completed

  • 4 1/2 hour cure - calculated based on datasheet

May need to assess if front bulkhead can be redone/reinforced

4.5 hour cure at 83.5 set point, (+3, -1 range) works? will cf cure properly?

Nov 9 2020

Aero:

• demolding rear bulkhead

• Pickup orbital sander for sanding - for sanding to be done

• Popping bottom panel out of the mold

Chassis:

• XP picking up VR3 tubes

• Begin sanding edges for welding preparation

Aero:

• Orbital sander, dremel were picked up

• Trying techniques for bottom panel removable.

• Rear bulkhead has been demolded

• Bottom panel demolding is doable but a bit fragile, layers can get thin in some areas which can lead to tears if not careful

Chassis:

• VR3 tubes picked up

• Sanding has not started

Popping out the bottom panel needs planning and techniques. Looking to pop out bottom panel Tuesday/Wednesday. Difficulty is unknown - pending how mold release was applied to the bottom panel.

Powder coating - if we are taping sections off for welding, but there are many sections that would need to be determined and taped-off. Note: although using epoxy would be stronger than painting.

Option 2: trimming the bulkheads to be fit into the chassis after the welding is completed. Kimberly will look into this tonight.

Nov. 10, 2020

Kimberly Liu, Colby Wang

Chassis:

• Sanding tubes

• Repositioning Chassis tubes and tightening everything

Aero:

• R.bulkhead Stencil and cut

• Bottom Panel pending planning results

• Clean up bay/supplies area

R bulkhead stencil ran into some issues with printer printable area, will try again tomorrow

Some bottom panel sanding done, cleaned for Montesano visit tomorrow

Chassis:

• sanding is done

• positioning of all chassis tubes will be finalized tomorrow (send out for welding early Thursday?)

bulkheads trimming: trim left and right sides of A-BH, C-BH should be okay as is (measured distances in cad to make sure the panels would be able to slide in).

Trimming the bulkheads may impact structural integrity of the chassis. FEA should be done? Tommy and Kimberly to sync this ASAP.

What are the Chassis sims without the bulkheads? (If we have time) This will determine how important the bulkheads are to the chassis.

Nov. 11, 2020

Chassis:

• Finalizing positioning of all chassis tubes for welding

• Put chassis on Rolling Table to put into Welding room

Aero:

• Trimming rear bulkhead

• Layup prep for front bulkhead - trip to Conestoga

• Meeting with Montesanto

• meeting with montesano went well

  • he’s v confused by the worms

  • our prepreg is v prone to becoming resin starved

• Trimmed rear bulkhead

• moved chassis to welding room

• continued working on positioning chassis tubes

• Finished preliminary sims for Chassis without Bulkheads.

• Arranged meeting with Matt to review sims on saturday

Nov. 12, 2020

Aero:

• test out bottom panel for removal (evening)

Chassis:

• Prepping for Welding to start Friday

• Figure out electrical mounting

• Gussets to be prepped for Monday

•  

Chassis:

• figured out electrical mounting

  • ran into some issues with aligning chassis tubes, but all are secured on the jig

• Gaps between chassis tubes - need to talk to Rob about a solution

Aero:

• Not much

Need an extra day for chassis welding, will have to push pick up for powder coating to Wednesday. Gussets cannot be done in the same day due to time.

To discuss plans about tubes dimensions. May need to bring to machine shop to trim.

Aero:

• Reinforcing is also a priority

• preparation for front bulkhead layup (higher priority since front bulkhead looks like it needs to be structural)

• small tests on bottom panel this weekend

• Jason calling/coming in this weekend

• Gussets to be reviewed tonight by Tommy and Kimberly

Nov. 13, 2020

Aero:

• Bottom panel tests

• Independent tasks + (front bulkhead prep)

• Material prep for test layups

• Sand the bottom panel (1 person - 1.5 hours)

Chassis:

• Reweld a part

• Seek advice from Rob about chassis

• Fix alignment of the tubes (Friday/end of Weekend to be ready for Monday)

• Provide drawing and material to Brian

Chassis:

• part has been re-welded and fits properly now

• got lots of helpful suggestions from Rob

  • will implement only a few due to time (tacking external references to the base, shims between gaps, sheet metal reinforcements along base tubes, pipe clamps across length/width of chassis)

  • we predicts the entire welding process will actually take 4-5 days instead of 2

• will be machining some components to add to the jig to help with alignment/positioning of tubes this weekend

• gussets will be done by end of day monday

Chassis:

• will need to push powder coating pick up to next monday

Nov. 14 2020

Battery modules laid out, instructions made.

Cleaned up the bay.

Nov. 15, 2020

Chassis:

• Took Rob’s suggestions and creating references for external dimensions for chassis

• Realigned all the tubes, no cutting required

• Demtool powder coating has been updated

Nov. 16, 2020

Chassis:

• machining shims, reinforcement tabs

• Finalize chassis for welding on Tuesday

Aero:

• Plan it out tbd

Chassis:

• Shims and reinforcement tabs have been added

• Ready for chassis welding tomorrow

• Picked up the Gussets from machine shop

Aero:

• Off-site: planning and looking at testing

Battery Box:

• Knowledge transfer for building half the module

• Bottom panel sanding

  • All areas for aero-chassis is ready

  • Trunk (nice to have areas - required if layup, 1-1.5 hr for one person)

• Pop out bottom panel

  • Side flanges have been popped out

Nov. 17, 2020

Chassis:

• number the gussets for location identification

• Welding (Pt.1): tack weld everything to hold everything together

• Temporarily A-Plane and C-Plane to keep it structurally sound. Will be untacked later

Aero:

• Prepping Front Bulkhead re-layup

  • Picking up carbon fiber (XP, Min)

  • Cutting nomex

  • Cutting adhesive film

Battery Box:

• Building module to half-built state

Chassis:

• Started tack welding today

• Some weren’t able to be tack welded - clamped instead

• Gaps were found: other than A-Plane, can be clamped closed or use shims to fill in

• Gussets have been numbered (ready for Friday)

Aero:

• Isabella cut the adhesive film

Troublesome areas:

• A-Plane: to be untacked in E3, shift the tubes around and close the gaps

Front Bulkhead Layup - Sat/Sunday

• Epoxy removal (have someone do it with Min), before this weekend, Thursday/Friday?

Wet Layup - details tomorrow

Nov. 18, 2020

Colby, Kimberly, Tommy

Chassis:

• Have everything tacked and ready

  • Fix B-Plane

• Full weld

• weld gussets (Friday)

• Welding (Pt. 2): full weld

• Independent Task (Kimberly - 30-1HR) - Colby

Aero:

• Cut adhesive film

• Carbon fiber pickup - XP & someone else?

  • Cut Carbon Fiber

• Cut Nomex

Chassis:

• tacked tubes that sit below the chassis, sanding

• Colby: Sorted nuts and bolts and tubes (unneeded portions of the jig)

Aero:

• XP and Brielle pick up carbon fibre

• Brielle and Filip cut out Nomex and carbon fibre

Nov 19, 2020

Chassis:

• fix up last b- pillar

• finish the tack welding, gusset and trunk tubes

Aero:

• Nothing

Chassis:

• Most of gussets tacked

• B-pillar tubes tacked

• Assembling trunk tubes jig

• Removed extrusions, undid nuts and bolts, put away

• CLEANED UP!!!!!!

Aero:

• Nothing

Full weld - requires Friday, Monday, half of Tuesday

Aero-chassis integration adhesive??

Nov. 20, 2020

Chassis:

• Tommy machining a few parts

• Tacking a few sections

• Start full weld

Aero:

• RESEARCH: non-destructive testing, refining simulations (Remote)

Nov. 21, 2020

Aero:

• A bit of bottom panel removal - a bit harder than expected

  • mold release is working but there is still some bonding left

Chassis:

• No updates

Need to decide on how the bottom panel removal will work.

Reach out to Graeme about removal.

Remaining work for bottom panel before chassis is complete:

• Pop out bottom panel

• “some sanding”

• cleaning area around / in bay

Nov. 22, 2020

Aero:

• No updates

Chassis:

• took dimensions of welded chassis

• review differences and update CAD for tomorrow

Nov. 23, 2020

Aero:

• prep work and begin testing

Chassis:

• get most of the welding done

Chassis:

• Rob continued with full weld - not update at the end of the day

Further panels manufacturing during aero-chassis limbo period dependent on bulkhead.

• Wheel cover can be started and done?

• Or prepping for side panel layup

• Or B-bulkhead

Nov. 24, 2020

Chassis:

• Finish full weld in morning

• Add trunk tubes

• Afternoon: taping areas for powder coating

Chassis:

• Continued full wld

• Weld A-Plane before powder coating

  • would be difficult to put the A-Plane in otherwise

• Finished taping areas for powder coating

Chassis will be welded in full for powder coating.

Bulkheads will be trimmed and inserted into full welded chassis afterwards. (A-bulkhead)

Simulation for bulkhead/chassis testing will need to be changed.

Nov. 25, 2020

Chassis:

• Continuing full weld

• Add trunk tubes

Chassis:

• Continuing full weld

Nov. 26, 2020

Chassis:

• Continuing full weld

• weld trunk tubes

Aero:

• Bottom Panel Sanding (1 Person - 1.5 hours)

Chassis:

• Full weld almost done

• Last few areas that are tacked to be welded tomorrow

This weekend:

Test putting chassis on bottom panel - if chassis tubes don’t sit perfectly flat

• If ~1-3mm, fill in with adhesive

• remember to tape off areas for powder coating that Rob removed during welding!!!

• To research worst case scenarios if the bottom panel doesn’t touch

Nov. 27, 2020

Tommy, Kimberly

Chassis:

• Weld last few tacked areas

• Reinforcements (4130) sheet metal

• Will meet with Rob tomorrow morning hopefully to finalize the last stage of welding

• Tommy will work on simulations for the second half of the day

Aero:

• Bottom Panel Sanding (1 person - 1.5 hours)

Misc:

• Check for Raceface Order

Powder coating pick-up Monday!

Nov 30, 2020

Kimberly

Chassis:

• Finishing welds

• aiming to send it out for powder coating on tuesday - will send out an email tomorrow during working hours

Aero:

• looking to redo front bulkhead (TBD)

• 9:30pm - Timeline meeting for leads to see what is feasible for this and next term

• Q: do we want to do stencils - already have - Min

• Seat belt tabs

Chassis:

• FINALLY FINISHED WELDING!

• Reapplied tape in certain areas for powder coating (1” away from welds) - (for A Plane reinforcements, bulkheads, cut down on B-Plane tubes prior to Aero-chassis integration)

Aero:

• CADing stencils for Fbulkheads

Brielle:

• was supposed to drill misumi spacers but don’t think the package arrived yet :(

A-Plane Reinforcement - need to sync up with Dynamics to see who will be doing this

Bulkhead gluing - ~1 day to cure

RBulkhead stencil - need to communicate with Seat belts tabs (Filip) and other dynamics items when creating

December 1, 2020

Chassis:

• Chassis will be picked up by Demtool in the morning

Aero:

• Printing and cutting stencil for bulkhead OR prepping bulkhead layup

Misc:

• Organize new PPE dropped off in the bay

• check Leif’s package

Chassis:

• CHASSIS HAS BEEN PICKED UP

Aero:

• Bottom panel was popped out (Kudos to Graeme and Brian for helping)

• Quality is good: stands on its own, stiff, needs to be supported by something on the ground

• Hood, Trunk are weak

Misc:

• misumi arrived

• summit arrived

Bulkhead testing (Wed/Thurs)

• Need to do a material inventory for specimen quantities

Reinforcements

• Top part of hood can be done while assembly

• Sides are trickier to reinforcement (dynamics is really close to bottom panel) - this is a research problem that needs to be reviewed

• Support chassis without damaging bottom mold

Future note:

• If delivering/picking up, Central Stores needs to know

Dec. 2, 2020

Chassis:

• N/A

Aero:

• Cutting F.Bulkhead from Stencil (not urgent anymore)

• Material inventory for testing

• Talk to Mark about testing

• Testing on Thursday

Misc:

• (ongoing) clearing bay area (e.g. unusable MDF)

• Misumi Dynamics Task

Misc:

• Misumi dynamics parts drilled out (put back in the package that they arrived in)

• Summit Racing arrived

• Need to machine Bellcrank clevis reinforcement

• Aerochassis Integration

• Stencils

  • R.Bulkhead need final locations for remaining items, e.g. seat belt tabs etc.

Dec. 3, 2020

Misc:

• Renzo: KWA/Krew pickup/delivery, Linamar pickup and deliveries

Aero:

• Potentially schedule stencil cutouts

Dynamics:

• schedule bellcrank sheet metal machining

Misc:

• Trip is complete!

Chassis:

Cutting bulkhead end of next week

Aero-chassis clarifications on Friday

• adhesive for Bulkheads may be delayed by dynamics welding

• Pending: chassis arrival, welding time, E3 welders

• Other items may need to be welded, i.e. interiors tube before bottom panel is adhered

Dec. 4, 2020

Chassis:

• Kimberly and Tommy heading to Demtool to take off tape

  • Picked up sandpaper to remove duct tape adhesive

  • Renzo is driving

Dynamics:

• machine bellcrank sheet metal

Misc:

• Rocketry’s Demtool Box to 2001

• Purchase Adhesives (10 cartridges of 50 mL)

8:00 PM Aero-Chassis meeting

• Emergency plan (due to exams, interviews, etc.)

• Aero-Chassis integration decisions

9:00 PM Onsite Meeting

Notes:

• Tommy will be remote W2021

• Poke Leif about Dynamics tasks

Dec. 11, 2020

Ricky, Micah

• Ricky finished assembling the battery modules up to the potting compound step

• Micah created glue-up jig for the potting compound - used some of the extra sample adhesives from Henkel

• More clamps ordered increase number of parallel assembly steps possible once potting compound arrives

• Also ordered some cutting fluid for use when cutting/drilling metals to extend tool life

Dec. 12, 2020

Chassis:

• Do dry-run for aero-chassis integration to check for potential problem areas

Aero:

• Ongoing material prep for bottom panel reinforcements during the week of Dec 14-18

• Trimming rear bulkheads on Monday at 12:30PM (Isabella, Brielle, Michael)

• Looking to do Bottom Panel Reinforcements Dec 18th (next weekend)

• envelope bag with bottom panel on top of the mold

Dynamics:

• Reviewing tasks and timeline

• looking for volunteers for tasks

Dec 14, 2020

Michael, Brielle, Isabella

So we completed the stencil for the cutout however the stencil we made turned to be bigger than the bulkhead and we weren’t able to trim the bulkhead because of this, the bulkhead is possibly to small, I discussed with Min a little bit about the situation and we can still use the stencil for cutout locations and we’ll deal with the size issue once we get the chassis back from demtool

Dec 15, 2020

Tommy, Min

Epoxy Adhesive arriving today.

Min+Tommy doing some material prep for Aero Layup

Dec 19, 2020

Chassis:

• 9AM - Chassis Arriving

  • Michael, Isabella

• Cutting down B-plane tubes

  • 1 person

• Take off powder coating (trial and error)

  • 2 person

• Last step: prepare dynamics welding for Monday

  • more sanding + bring to welding room

  • 3 person

Aero:

Overview:

• Plan is to cure the Bottom Panel Tuesday morning

  • all day-ish

Saturday:

• working on setting up vacuum bagging for bottom panel, trying to hold vacuum and prevent errors

  • 1-2 people

  • whenever people are available

  • afternoon/evening

• front and rear bulkhead prep

  • isabella and michael

Sunday

• testing oven setup, bulkheads prep

  • 1-2 people

  • morning

Monday:

• placing carbon fibre and core onto bottom panel + doing final vacuum bagging monday night

  • 3-4 people

  • all day-ish