More to come in the next weeks…
Design start of cockpit internals, fitting radiators and finishing rear suspension components.
As uni stuff (exams) is coming to an end slowly, I’ve a bit more time left now and car progress will speed a bit up during the next time.
Over the last few weeks, I’ve done quite a lot of (more or less) small detail work on the car. First of all, I’ve found a suitable grid for protecting my radiators (metal grid with about 1mm mesh size). After fitting this to the rad ducts, I was finally able to fix the radiators to the car. A bit of detail work is still missing there, i.e. proper sealing, pipes, etc..
The next building site was the finishing of all the rear suspension components with clear lacquer. As I don’t have a proper paint shop (room), I had to wait for acceptable outside temperatures for lacquering on our balcony.
Next point are the cockpit internals. As I have to wait a lot during finishing and mounting the rear suspension, I need a site where I can build at and not touching the car a lot. So seat is more ore less done (picture series below), steering wheel (picture series below) is well on the way and some small bits such as “dashboard” (that’s the tiny bit at the drivers right hand side with fire extinguisher and ignition button on it) or belts are missing.
There’s not too much stuff missing at the car now. Front suspension, brakes, wheels and engine cover. Nevertheless, I expect finishing the car not before middle of autumn – maybe October.
as you may know, in 2012 Rob Marshall, Chief Designer of Red Bull Technology, respectively Red Bull Racing, offered me a student placement job at the Formula 1 team. In August 2013, I started this challenge as a composite design engineer. Designing parts all over the car (RB10), I gained a very lot of experience in race car design and the work in a F1 team. In October 2014, I returned to Uni (Graz University of Technology), to finish my master studies in mechanical engineering. Here is a short video clip, produced by ServusTV which was part of a documentation about Austrian engineers in motorsports.
Summary report of December, January, February
Design start of front and rear suspension, manufacturing rear suspension and barge boards.
In December I started designing the front and rear suspension. Designing the suspension is one process, to get the suspension properly onto the car is a different step… The design of the suspension is based on the chassis/gearbox mounting points and the wheel position. The manufacturing of the rear suspension is almost done, just the pullrod is missing. The positioning of the upright relative to the chassis is one of the most essential points in the building process as it defines the position of the car above the ground in finished stage. For this reason I did a jig to position the upright correctly and connect it via the suspension arms with the chassis.
Also the barge boards are already manufactured and are awaiting the lacquering process (as well as all the suspension elements).
Slowest progress ever…
Redesign of cooling ducts, finishing airbox, starting with electronics design and fitting process of the radiators.
There was a little progress over the summer since the last post. My intended finishing date for the car was something about in spring 2017, but with the current progress rate it could move into the summer. But one after the other:
- I finished the redesign of the side pod cooling ducts. I did a design, when I built the monocoque back in autumn ’13, but in spring this year they proved to have a wrong size and position to fit the radiators (collisions with floor and exhaust end pipe). So, after the redesign they look fine, but it’s still a huge challenge to manage this tight packaging. I see more problems coming when designing the engine cover.
- Quick note on the airbox: All done, lacquered, fitted and sealed. No problems at all.
- A few weeks ago, I started with the electronics design. The electronics are fitted in the side pods each below the radiators, below the drivers seat and at the front of the monocoque. The rh side pod is already filled up with just missing out the cooling duct for one of the boxes. Btw – all electronics data are free available at mclarenelectronics.com – thanks MES for that!
- At the mo, I’m fighting to get the radiators properly fitted to the ducts.
End of “creative break”
Finishing rear wing and start of of internal duct design. Furthermore – finishing my Bachelor degree.
As my Facebook followers might have noticed, I had something like a creative break on building my Lotus. Main reason for this is to find on uni. As I was finishing my BSc degree in Mechanical Engineering and starting my Master studies, there was a lot of stuff to execute. I guess, now in the summer month, there should be much more progress on the car than during the past few month.
Two days ago, I restarted working on my E21. The last few bits I did on the car was assembling, painting and fitting the rear wing to the car.
After removing the existing side pod cooling ducts due to non-compatible size of themselves (a design error), I started to design new one with all the given circumstances. The left cooling duct houses the water and gearbox-oil radiator, the left one engine-oil and ERS radiator. I’m still not completely sure, where the hydraulics cooler sits. Probably at the top of the monocoque below the airbox. As you will see in the pictures below, it’s a tough challenge to achieve the extremely tight packaging, especially in the area around the exhaust system and the radiators.
The airbox is a bit more complex than the previous airboxes I’ve built so far, but the design process didn’t showed any big problems.
Next things on the to-do list are finishing these ducts, than design and build all the electronics sitting in the side pods (ECU, PCU,…) and the PDRS ductings. Now let’s take a look onto the car.
Something about Rear Crash Structure, ERS Battery, Exhaust System and Rear Wing
Pretty long time went on since my last post. Some work on uni, some work in Formula Student and a move into a new flat prohibited me working a lot on the Lotus. Nevertheless there are some news since the last report.
Where should I start? Probably it’s worth mentioning at the beginning that the gearbox is now finally fitted to the engine. This comes along with the finishing of the hydraulics pump/hydraulics system which sits on the right hand side of the engine beside/behind the oil pump.
After fitting the gearbox to the engine, I started working on the rear crash structure. Nothing very impressive or interessting to tell about it. With the fit of the rear crash to the gearbox, the car reached its full lenght of 507mm. It should actually be 508mm long, but one mm is within the acceptable tolerance (indeed it’s less than 0.2% deviation). Of course the rear crash structure is hollow to allow the fit of a working rear light.
Another work which was done within the last two month is the production and fit of the ERS-battery. Although the battery isn’t visible on the finished car, I produced a simple battery model, just as a “nice to have item”.
Next point on my (still endless long) to-do-list was the manufacturing of the exhaust manifold. Always a very demanding and not really liked work. For the first time in my modelling career, I produced an exhaust system, lacquered with a chrome spray. And it looks convincing. The system is already fitted on the car. And the packaging is stunning. I had quite a few problems to make the underbody fit to the car with the mounted exhaust manifolds.
Subsequently I started working on the rear wing. End plates and flaps are finished, DRS and beam wing are still under construction.
There are also some bad news. I had to grind off the whole cooling ducts in the side pods as they were too wide at the bottom. Coming along with this, my radiators are also worthless and need to be redesigned. Luckily radiators are not very demanding to design and build.
The car currently has about 3100 parts. About expected 2500 more to come.
At the end a nice video of the first try to fit the underbody to the chassis.
Finishing Underbody and Coanda Exhaust
Finally, the underbody is finished. What happened since the last post? Beside manufacturing the Coanda exhausts, where I used a colour spray lacquer (chrome) for the first time, I added loads and loads of small features to the floor. That means stuff like skid blocks, heat shields, IR cam housings, tyre vanes, diffuser strakes, diffuser gurney, live locks, some sponsor/partner labels, reinforcement stuff, bolts, skid planks or CFRP textures.
As I mentioned, I introduced some new techniques, namely the chrome spray lacquer for the Coanda exhaust groove for example. After it initially worked flawless, it happened that I run a bit into trouble when applying the final layer of clear lacquer. On the chrome can it says, it’s not compatible with clear lacquer, but I thought, clear lacquer will just run off the chrome surface. Instead, it dissolved most of the chrome…
Another new technique was, to use a special glue for applying big-surfaced CFRP areas. Previously, if I bonded on the CFRP texture (90g/m² paper) with my usual glue, it happened that the paper started to dent. The new glue is much less aggressive and does not show this properties.
Enough blathered, here are some pics of 448 glued paper snippets: