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

W21/S21 - Aero-Chassis Integration Resources

Timeline and Task Tracker:

 Project Status and Updates

See the “Aero-Chassis Projects” section for project-specific pages.

https://docs.google.com/presentation/d/11CjKaAsIzviGp7nR2q-w4SpiHLnWtW-IfKPLS8wMUfs/edit#slide=id.gb447a16bf8_0_41

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

Part Bonded to Chassis

No. of 50mL Cartridges Used

Front + Rear Bulkheads

2.5

Bottom Panel

B-Bulkhead

Floor Panels

Side Panels

Panel Integration Plans :

Integration Timeline and Instructions

Term

Panel(s)

Details

F20

  • A, C Bulkheads

N/A

S21

  • Bottom Panel

Bottom Panel-Chassis Integration

  • Floor Panels

Floor Panel-Chassis Integration

  • B-Bulkhead

B-Bulkhead Assembly Plan

F21

[ Dynamics Assembly / Panel Manufacturing ]

W22

  • Bridges

Bridges Integration

  • Side Panels

SIDE PANEL(S)-CHASSIS INTEGRATION

  • Roof (removable)

Roof Panel -- Aero-Chassis Integration

  • Trunk (removable)

Trunk Hinges

  • Wheel Covers

Wheel Cover Integration - Development

[ Thermoformed Panels Complete ]

  • Windows

  • Hood

Hood Panel Integration

  • Windshield (removable)

Windshield Panel Fastening

  • Headlights

Lights DFMA

  • Doors

S22

[ Panel Painting, Sealing, Waterproofing ]

Panel Specific Mounting Information

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

Panel Fastening/Bonding Details

Panel Trimming Groups, Order & Details

Bottom Panel and Flats

  1. Bottom Panel - trimmed using mold outline

  2. Bulkheads - trimmed using a stencil

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

Main Body Panels

  1. Bridges - trimmed using mold outline

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

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

  4. Roof - trimmed using ???, clamp to chassis, trim to fit with side panels, bridges

Thermoformed and Surrounding Panels

  1. Windows - trimmed using mold outline?, trim/fit to door flanges

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

  3. Windshield - trimmed using mold outline?, trim/fit to bridge/side panel/hood flanges

  4. Headlights - trimmed using mold outline?, trim/fit to hood, side panel flanges

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

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