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Summary of Bonding Methods

  • Adhesives

    • Carbon fiber to flat steel tube/surface (bottom panel, bulkheads, bridges, trunk, doors)

    • Carbon fiber to perforated steel surface (side panel, roof panel)

    • carbon fiber to carbon fiber (bridges, hood)

    • Carbon fiber to polycarbonate (headlights, windows)

  • Mechanical Fasteners

    • carbon fiber to polycarbonate (windshield)

    • carbon fiber to carbon fiber (wheel cover)

Panel Specific Information

Panel

QTY

Fixed?

Substrate 1 (panel)

Substrate 2

Bonding Method

Details

Relevant Confluence Pages

Images

Bottom Panel

1

Y

Carbon fiber

Steel Tube (chassis)

adhesive

Directly bonded to chassis tubes (bottom, catamaran and trunk)

Bottom Panel-Chassis Integration

B-Bulkhead

2

Y

Carbon fiber

Steel Tube (chassis)

adhesive

Directly bonded to chassis tubes (B-pillar).

B-Bulkhead Assembly Plan

Floor Panels

4

Y

Carbon fiber

Steel Tube (chassis)

adhesive

Directly bonded to chassis tubes (bottom reinforcements).

Floor Panel-Chassis Integration

Bridges

6

Y

Carbon fiber

Steel Tube (chassis)
Carbon fiber (side)

adhesive

Directly bonded to chassis tubes (round) OR side panel.

Bridges Integration Plan

Side Panels

2

Y

Carbon fiber

Carbon fiber (bridge)

Steel brackets (perforated)

adhesive

Top and bottom edges are bonded to the chassis.
Middle sections are reinforced with 2 interlocking brackets: 1 adhered to panel, the other bolted to the chassis

SIDE PANEL(S)-CHASSIS INTEGRATION

Roof

1

N

Carbon fiber

Steel (perforate base stud)

adhesive

(Hinge?)

Base stud adhered to inner surface of panel and secured through a welded tab on the chassis.

Roof Panel -- Aero-Chassis Integration

Trunk

1

N

Carbon fiber

steel (hinge) ?

adhesive

Hinge, latch and props

Trunk Hinges Trunk Latch

Doors

4

N

Carbon fiber

steel (hinge) ?

adhesive

Panel glued to a bracket which is fastened to hinge. The hinge is bolted to chassis.

Hood

1

Y

Carbon fiber

Carbon fiber (side, bottom panels)

adhesive

Bonding areas along side panel and bottom panel.

Hood + Windshield Panel Integration Project

Wheel Covers

4

N

Carbon fiber

Carbon fiber (side panel)

Fasteners (Bolt)

Adhesive mount nut on inside face of side panel flange. Bolt through wheel cover and side panel.

Wheel Cover Integration - Development

Windows

4

Y

Polycarbonate

Carbon fiber (doors)

adhesive

PC panel adhered to CF flanges

Window Panel Integration Plan

Windshield

1

N

Polycarbonate

Carbon fiber (bridge, hood, sides)

Quarter-turn fasteners

Holes need to be drilled along borders

Hood + Windshield Panel Integration Project

Windshield Fastening

Headlights

2

Y

Polycarbonate

Carbon fiber (hood, sides)

adhesive

PC panel adhered to CF flanges

Lights DFMA

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