Cockpit electronics, suspension stuff, exhaust system, brake discs, internal aero and more.
This post sumarizes the work I’ve done over the past two month. A lot of small stuff like fuel fillers or electronic boxes, but also massive projects like front-and rear suspension and exhaust system.
The completion of the car is optimistically aimed to early spring, maybe March. Unfortunately it is too cold now, to do the paint jobs on the balcony. So the flat is a bit smelly from time to time. 😀
The to-do-list is pretty short now:
- Cockpit padding
- Brake calipers and cooling ducts
- Wheels, wheel hubs, wheel nuts
- Internal aero
- Engine cover
- Rear light
Next to come are the brakes.
Brake fluid reservoirs, exhaust pipes, fire extinguisher, radiator pipes, beer and more…
Nice progress over the last days. There’s not a lot missing any more. Main sites are front suspension, brakes, brake ducts, wheels and engine cover.
When I come to the end of a car build, I usually create a to do list with all the stuff on which is left. On this list I rate all elements with
+ which means, it’s an easy, quick and nice, simple to build element
~ which means, it’s a pretty simple element, but takes it’s time and is not that nice to manufacture
– which means, it takes a lot of time to build the element
Front suspension, cockpit padding and engine cover are the last three minus elements (maybe also the rims).
The components and assemblies, I produced during the last few days are stuff like exhaust end pipes (with their helmholtz resonater – more on that in picture caption below), fire extinguisher, brake bias lever, dashboard, roll sensor, brake fluid reservoirs, pitot tube and some electronic stuff at the front end of the chassis.
Beside all this, I created a rim instruction. So the rim design is already done.
Unfortunately I lost the drive shafts during the summer… 😦 So light delay at the rear suspension build.
At the moment, the car is at about 4000 parts.
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.