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The Firewall is made of a sandwich panel of 6 layers of 200 gsm bidirectional basalt fiber with a sheet of Nomex Honeycomb in the middle. It also has a layer of 0.64mm thick 6061 Aluminum facing the tractive system. I used Basalt because it had the highest resistivity and acceptable tensile strength. The Nomex Honeycomb adds an air gap which improves the area moment of interia and the thermal resistivity of the panel leading to greater stiffness and themral insulation without adding more layers of basalt.
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Harness tab was designed to be able withstand 15,000N of tearout load per tab based on rules from FSAE.
The tabs were designed to be manufactured from rectangular steel tubing so that the bolts were in double shear while being easy and efficient to manufacture since there it was milled out of correctly sized tube rather than a solid block of steel. Although 2 tabs cut from 1/8" sheet metal could have been used, it would have been very challenging to weld the inside edge of the tab as required by rules. The hardware is M12 high-strength alloy steel shouldered bolts.
The factor of safety for the harness tab is 2.1.
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