Stuart's Work in progress

Post up a thread for your EV. Progress pics, description and assorted alliteration
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stuartri
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Post by stuartri »

Just a sneak peek of my work in progress. Hope you like. Trying to get this stuff done to get onto the fun part the electronics and engine management systems.


Stuart
Image

Image

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Adverse Effects
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Post by Adverse Effects »

that is an interesting look

not sure if i like it or not

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Post by Nevilleh »

Are you planning to actually build a thing that looks like that?

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stuartri
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Post by stuartri »

Yes already started the build.

stuart

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Post by Johny »

Maybe it's just the colour but it looks a lot like this one.
http://www.gaiatransport.com/Image

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Post by Faz »

Are you planning on making this a licensed vehicle or is it a toy/go-kart?

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Post by stuartri »

Faz short term goal is to get the car up and running to race in WA.

Stuart

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Post by Faz »

Cool.
Have you got an idea of motor and battery specs yet?

What material are you planning to construct it from?
Last edited by Faz on Thu, 13 Oct 2011, 10:57, edited 1 time in total.

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Post by stuartri »

Faz,
Thanks for your interest.

From the bodywork and frame side of things I have a couple of options but initially trying to keep costs low and have a repeatable manufacturing process while the concept is being developed. Besides this area is not where my main skill is so just pushing through.

Bodywork
1. Moulded plastic
2. Fribreglass
3. Aluminium

I think while the concept id developing Fibre glass is the most realistic.

Space Frame
1. Chrome Molley
2. Aluminium

Battery / Motor Combination
This decision initially will be driven by the EVChallenge regulations however I am looking at sourcing options overseas at present.I will keep an update on this.

The cannopy parts are getting profile cut next week to make my buck so I have added another Pic - work in progress



Image

Image

Thanks Stuart
Last edited by stuartri on Wed, 19 Oct 2011, 13:46, edited 1 time in total.

Faz
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Post by Faz »

I've always seen the problem of constructing a car for the ev challenge in the rule that the costs must not exceed $1200. Even if I were to fibreglass my own shell (taking into account producing the mould) the cost of the chassis would be about half (or more) of the allowable limit. Which then doesn't allow enough money for the batteries and motor.

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Post by stuartri »

Faz you could try a monocoque design. Again long term the EV challenge rules are too restrictive. I have requested that they allow for an advanced technology class more akin to the electrathon in US.

Stuart

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Richo
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Post by Richo »

The only problem I have with that is it usually comes down to who has the most money wins.
So the short answer is NO but the long answer is YES.
Help prevent road rage - get outta my way!

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Post by stuartri »

Richo were you referring to an advanced technology class? I still feel that it should be capped as well however it should be more around 2K-3K and incorporate more safety and promote people doing some more development. Realistically in $1200 budget preformance will be capped very soon without an ability to innovate.

Stuart

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Post by Richo »

If it was an open cheque book that's mostly how they turn out.
But a limit of 2-3K may still be restrictive in an advanced class.

How much do they spend on th US ones?
So the short answer is NO but the long answer is YES.
Help prevent road rage - get outta my way!

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Post by stuartri »

Richo,
I will find another thread to reply to this in when I can find something appropriate.
Again thanks for your comments greatly appreciated.

Stuart

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Post by stuartri »

A friend of mine Paul has kindly assisted with a concept rendering. Early days yet but really appreciate it Paul, thanks again for your efforts.

Image

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Richo
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Post by Richo »

Would be cool you made it hubless.
But I doubt the $1200 budget will allow for that tho.

How thin and light do you think the shell will be?
There is a crossover from improved aerodynamics vs extra weight.

How bout the top - will it be see through or have a small window?
I'd imagine it would be hard to get a nice clear curved top.
So the short answer is NO but the long answer is YES.
Help prevent road rage - get outta my way!

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Post by stuartri »

Thanks for that Richo,
Yes hubless would be nice but will be going with rims.

The plan is to design the car not to the constraints of the EVChallenge as the budget is too low. I will have to race next year without the shell as that would not fit in the budget. I am making it modular so I can attach parts that are suitable for the EV Challenge but not restrict the possibilitie of the vehicle.

Researching materials and manufacturing processes so not sure of weight yet of the body. Researching Glass re-inforced injection moulded nylon, very strong and light for the roof , headlights and tail lights. Initial thoughts is the cannopy will be clear tinted but things may change after more progress on the buck is achieved.

Last edited by stuartri on Wed, 19 Oct 2011, 12:10, edited 1 time in total.

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Post by stuartri »

Well I have had the profile cutting done for the roof form as per earlier pictures so thanks to Stephan from Stefco Pty Ltd CNC Router Services for the profile cutting. He sent me some pics so am looking to pick up the templates.

Please see below


Image

Image

Stuart
Last edited by stuartri on Wed, 19 Oct 2011, 13:38, edited 1 time in total.

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Post by stuartri »


Picked up the profile cuts today so will be working on the cannopy over the weekend to assemble it. Am looking at filling between the wood sections with H Grade polystyrene and will be buying a polystyrene cutter. Next post will be with the connopy template all ready and the poly styrene fill.

Here are a couple more pics. Only a couple of artifacts to fix up on the front but nothing major. Maybe I better work on better mannequin in the car so the proportions are clearer inside the cabin.

Image
Image

Stuart
Last edited by stuartri on Thu, 20 Oct 2011, 18:02, edited 1 time in total.

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Post by stuartri »

Well progress has been a little slower than I would like to see but having the 3D model does make it very easy to progress when I get the time. Next step will be to machine the the other panel sections of the buck so that I can assemble it and start on shaping the high density poly styrene in early January.

Here is the next CAD view of the profile cuts. Will try and get Stefco to get them done before christmas. Fingers crossed.

Image


Regards Stuart

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Post by stuartri »

It's been a while since my last post so time for an update.
Missed the cutoff for panel machining before Christmas so scheduled for 2weeks time.

While waiting for machining going through calculations for optimal motor selection. Am looking to source a switched reluctance motor and controller. If anyone has supplier contact details I would greatly appreciate it.

Work schedule
1. Cad model of body (complete)
2. Fabricate canopy (in progress) - working on my vacuum forming kit
3. Fabricate body buck sections (in progress)
4. Source supplier for 500 watt switched reluctance motor and controller
5. Finalise rear swing arm sdesign and incorporate into cad

Image
Last edited by stuartri on Tue, 10 Jan 2012, 14:17, edited 1 time in total.

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Post by stuartri »

Putting together all views then renderings of the buck body before the final profile cut

3 wheel sports electric concept

Image

The fornt side profile shows a little work to do on the rear of the car.

Many thanks again go out to Paul for the rendering. A lot of nagging and a nice bottle of alcohol got it over the line lol.

Stuart
Last edited by stuartri on Sat, 25 Feb 2012, 09:24, edited 1 time in total.

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Post by stuartri »

Creating panels from the model which will form part of the buck froms
The lateral panels have been formed as per above posts now working on the longitudinal panels that will then be slotted in.

Image

The working area of the CNC profile cutter is 1200mm x 900mm so have to make sure that longitudinal sections do not exceed this.


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Post by stuartri »

I have now completed the longitudinal panel sections that will form part of the buck. Have rendered them in a wood finish to get a sence of what the machined parts will look like.

Image

The next step is to re-do the lateral sections then render them in a wood finish. After that I will create the slotted forms that I can send off for CNC profile cutting.

Found a couple of issues with the profile above so I have cleaned this up now. Refer to the image below.

Image

Stuart
Last edited by stuartri on Mon, 05 Mar 2012, 14:46, edited 1 time in total.

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