Racecar Portfolio 20 Weeks

Kyler Kitani

54602164

12/19/14

ANTEATER RACING PORTFOLIO (SAVAGE)

WEEK 1- DRAWING, JIGGING, AND PROFILING THE CHASSIS

Description: We used SolidWorks to dimension parts of the

chassis and printed drawings to use for a jig. We drilled holes and

attached the wood blocks to the board to hold the parts in place.

Using the dimensions on the drawings, we began measuring the

steel tubing with a tape measure. Since we didn’t have a chop saw,

we had to cut the tubing with a hacksaw. After cutting pieces to

the correct length we began filing the tubes so they fit together

well.

Documents:

Photos

Drivetrain/suspension support drawing

Assisted by: Luis Renteria, Harrison Lu, Veronica Woen, other

chassis members

WEEK 2- CUTTING AND PROFILING THE CHASSIS

Description: First we measured and cut the steel tubing for the front bulkhead

of the chassis. Then we used hand files and a grinder to profile the tubes to fit

tightly together in the jig. For the front and main roll hoop of the chassis we

had to bend it to make a curvature. After we finished profiling all the parts in

the jig, we began tack welding the members together.

Documents:

Photos

Assisted by: Luis Renteria, Harrison Lu, Chris Ponce, Sean, and other Chassis

members

WEEK 3 - CUTTING, PROFILING, AND WELDING THE CHASSIS

Description: This week we continued to work on profiling tubes and

tacking them together. We completed the front bulk head and bottom

panel on the chassis and will begin on the side impact and suspension

panels next week. We also used a dremel to remove one of the tubes

we made a mistake on and will work on profiling a new one next

week.

Documents: Photos

Assisted by: Luis Renteria, Harrison Lu, Chris

Ponce, Sean, Veronica, James and other Chassis

members

WEEK 4 – PROFILING AND WELDING THE CHASSIS

Description: This week we continued working on the chassis

and made good progress. We found a notcher which sped up the

profiling process tremendously. We completed the side panels

and next week we will be working on the cock pit and the

engine bay. Currently we are one week ahead of schedule.

Documents: Photos

Assisted by: Luis Renteria, Harrison Lu, Chris Ponce, Michael

Rodriguez, Veronica, James, Michael, and other members

WEEK 5 – SOLIDWORKS TESTING AND JIGGING

Description: This week we performed FEA tests on the chassis by

looking up the requirements in the FSAE rule book. Pictured below

is the results from the stress and displacement test. We also began

jigging for the engine bay of the chassis. Next week we will try to

finish profiling and welding the back side of the chassis.

Documents: Photos and Solidworks FEA

Assisted by: Luis Renteria, Harrison Lu, Chris Ponce, Michael

Rodriguez, Veronica, James, Michael, and other members


Description: This week we finished profiling and assembling the

engine bay. We ran into some difficulties because our notcher broke,

which forced us to hand profile again. Also we discovered that one of

our jig drawings was off, and we had to remake two pieces. We are on

schedule and only have to profile and tack weld 8 more members to

complete the chassis.

Documents: Photos

Assisted By: Luis Renteria, Harrison Lu, Chris

Ponce, Veronica, James, Michael, and other

members


Description: This week we started working on the side

panel tubes that connect the front and main roll hoop. We

are one tube away from finishing that section. We also

discovered that the engine won’t fit properly in the

engine bay and will have to extend it longer. Next

quarter we will fix the engine bay and we will continue

to focus on finishing the rest of the chassis in the next

two weeks.

Documents: Photos

Assisted By: Luis Renteria, Harrison Lu, Chris

Ponce, Veronica, James, Michael, and other

members

WEEK 8 - PROFILING AND WELDING THE CHASSIS

Description: This week we completed the

remaining side impact tubes and tack welded it. We

also performed tests on it and calculated equations

for the front impact test. Next week we will fully

weld the front bulkhead and begin cleaning the rust

off the chassis. We also began discussing colors to

paint the chassis and the methods of painting.

Documents: Photos and paper

Assisted by: Luis Renteria, Harrison Lu, Veronica,

James, Michael, and other members

WEEK 9 - CLEANING AND WELDING THE CHASSIS

Description: This week we cleaned the rust off the chassis using grade 2 and 3

steel wool and WD-40. Since our engine bay is too small for the R6 engine, we

measured the dimensions and used Solidworks to adjust our engine bay so the R6

engine will fit. On Saturday we completely welded the front bulk head of the

chassis along with tacking the suspension arms and suspension mounts. Next week

we will continue to work on adjusting the engine bay and clean the chassis again to

look nice for the design review.

Documents: Photos, Drawings

Assisted by: Luis Renteria, Harrison Lu,

Veronica, James, Michael, and other members

Description: This week we welded the

suspension arm and tabs on the chassis and

tacked parts of the steering. We also cleaned

up the chassis with WD-40 to prevent rust and

make it look nice for the design review. One

day we researched paint and different coats.

An excel sheet was created to keep record of

our results. Next quarter we will be fixing the

engine bay and painting the chassis. The fall

design review went well and we presented our

project.

Documents: Photos, Excel Sheet

Assisted by: Luis Renteria, Harrison Lu,

Veronica, James, Michael, and other members

WEEK 10 – FINALIZING/PREPARING AND FALL DESIGN REVIEW

Week 11 – Redesigning Chassis Engine Bay

Description: This week we worked on the redesign of the

engine bay. We used SolidWorks to figure out the

clearance and exact distances needed for the engine and

sprocket to fit. Also we used hacksaws to remove the

engine bay from the chassis. When using the hacksaw

we were very careful not to damage the main or front roll

hoops because the FSAE rules. Next week we will begin

manufacturing new members to remake the engine bay.

Then we will tack weld them in place and check the

packaging.

Documents: Photos

Assisted By: Luis Renteria, Harrison Lu, Veronica Woen,

James

Week 12 – Redesigning of the Engine

Bay and Track Day

Description: This week we continued to redesign the engine

bay. We did a dry fit of the engine and sprocket and

measured the amount we needed to extend it. Then we

looked at the SolidWorks model to solidify our

measurements. On Saturday we also had track day and I was

able to drive Beta. Unfortunately I wasn’t able to drive Delta

because it broke down during track day.

Documents: Photos


James

Week 13 – Manufacturing of Extended

Engine Bay

Description: This week we worked on manufacturing the

extended members of the engine bay. First we measured the

length of the tubing needed. Then we cut and profiled four

of the ten members. We were very cautious when making

the new members because we do not have much extra

material. After profiling them we tack welded them in

place. This week we will finish the remaining members and

work to finish the chassis.

Documents: Photos


James

Week 14 – Completed the Manufacturing

of the Extended Engine Bay

Description: This week we finished the remaining 6 members of the engine

bay. We also tacked the entire engine bay together and are ready to begin fully

welding parts of the chassis. Also we began to assist the body team to mock up

the body of the car. Next week we will weld the chassis and fix some of our old

welds on the front bulkhead.

Documents: Photos

Assisted By: Luis Renteria, Harrison Lu, Veronica Woen, James Lee

Week 15 – Welding the Chassis and

Start Required Documentation

Description: This week we practiced our welding and began welding

the remaining parts of the chassis. We began taking a look at the

required documents we need to fill out for the chassis. We also

worked with the body team to assist with the mock up. Next week

we will finish welding the chassis and fill out the documents. We

will also begin looking into the impact attenuator.

Documents: Photos

Assisted By: Luis Renteria, Harrison Lu, Veronica Woen, James Lee

Week 16 – Welding the Chassis and

Manufacturing the Body

Description: This week we fully welded the members of

the engine bay. Before welding we cleaned each joint to

remove the rust to ensure we produced sufficient welds.

We also started working with the body team to fit and

shape the sheet aluminum to our chassis. Next week we

will finish welding the remaining joints that are not

finished in the side impact area. Also we will assist

suspension and body in their manufacturing process.

Documents: Photos


James Lee

Week 17 – Filling Weld Holes and

Mounting the Engine

Description: This week we checked all the welds on the

chassis and filled the holes that were found. We also helped

the engine team mount the engine in the chassis with the lift.

We aligned the engine and tied it in place and began making

engine mounts. Unfortunately we were only able to make and

tack weld the top engine mounts. Next week we will finish the

bottom mounts and begin helping suspension team so we can

get the mounts attached.

Documents: Photos


James Lee

Week 18 – Finish Mounting of the

Engine and FEA Testing of the Chassis

Description: This week FEA testing of the chassis was a

main focus. We performed front and side impact, torsional

rigidity, and buckling tests on the Savage chassis. Also, FEA

was performed following the alternate frame rules in the

FSAE handbook. Over the weekend we aligned the engine in

the chassis and finished profiling and tack welding the

bottom mounts. We ran into an issue with two of the bottom

mounts because it was very difficult to profile due to the

angle and alignment. To overcome this, longer engine mount

material may need to be purchased. Next week we will finish

welding suspension on the chassis and fixing the two bottom

engine mounts.

Documents: Photos and SolidWorks FEA


James Lee

Week 19 – Torsional Rigidity,

Suspension, and Fixing Chassis Holes

Description: This week we profiled 13 gauge steel tubing to

fill the holes we had in the engine bay. There were a total of

4 holes that we filled. Over the weekend we helped

suspension mount on their tabs, uprights, and rockers. We

also attempted to perform a torsional rigidity test on our

chassis but were unsuccessful because it was difficult to

clamp our lever arm onto the chassis without damaging any

of the members

Documents: Photos


James Lee

Week 20 – Winter Design Review

Description: This week our team pushed hard to accomplish

our goal of a rolling chassis at the winter design review.

The chassis team worked on designing end caps in

SolidWorks to cover the 12 tube holes. After designing

them, we 3D printed the end caps in RapidTech. We also

helped suspension team weld their parts onto the chassis.

The design review was a huge success and it was great to

see the result of all our hard work this quarter.

Documents: Photos

Assisted By: Luis Renteria, Harrison Lu,

Veronica Woen, James Lee