#### Body/Cockpit/Safety
System assembly that I designed (excluding frame)
Nosecone
Mold Manufacturing
Infusion Layup Setup
Resin Infusion
Post-Processing
NC11
Post-Vinyl
NC12
Firewall:
Electrically and Thermally Insulative, Ballistically Protective
Materials
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
that increases the area moment of inertia and the panel’s thermal
resistance, improving stiffness and thermal insulation without adding
more basalt layers.
Design
CAD
FW3
Laser-cut plywood prototype
Lower Firewall Manufacturing
Post-Processed
Firewall
Upper Firewall Manufacturing
Post Processed
UF4
Anti-Intrusion Plate
and Impact Attenuator
AIP Welding
Impact Attenuator Adhesion
AIP
Harness Tabs
Harness tab was designed to be able to withstand 15,000 N of tear-out
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 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. Used M12 high-strength
alloy steel shouldered bolts.
The factor of safety for the harness tab is 2.1.
Drivetrain & Accumulator
Mounting
Drivetrain Mounting Fixture
Fixture
Drivetrain Tabs Tack Welded
Tacked
My
friend and I welding the accumulator Tabs under intense time
pressure
#### Body/Cockpit/Safety
System assembly that I designed (excluding frame) 
