manufacturing wind screen arrangement and doors

The last few days I spent a little time on developing and designing the wind screen with its sunblind and panel. That’s for sure one of the most challanging part of the car. Especially the sunblind with its ellipsoid like shape. First I had in mind, that I’ll be able to produce that piece in one part. But I recognised that its not possible to do that in paper. At the end it got a three part item. I’m not really happy with this, but I think it’s not possible to do it better. There were a few points where I thought to try to make it in plastic…

Now there are only a few things missing till I can finish the monocoque with a mat lacquer – the Audi isn’t clear polished like an  F1 car.

That means, that I finally can start with the manufacturing of the engine/gearbox part next week. The week before last, I also did the first drawings for the gearbox beside learning. So there the main research is done also.

The right hand side door. The outside is almost finished. Only the opener and the hinge adapters are missing. The inside is still raw.

Here you can see the jig with the six different parts for the windscreen-sun blind arrangement.

Here are the six parts of the arrangement. At the most front the wind panel, than the main screen, the lower part of the sunblind and at the rear the three parts of the ellipsoid like main part of the sunblind. The numbers on the different parts illustrate the number of the version of the part. The rhomb means that it’s the final part.

Finally the monocoque with the mounted screen-blind arrangement.

The end result of the sunblind isn’t completely satisfactory for me (it should be one single part). But I think, I could not do it better.

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About paulsf1

My name is Paul Bischof. I’m a student in mechanical engineering at the Technical University of Graz in Austria, expected finishing in February 2016. Since I was eight years old, I am building model planes out of paperboard. Since 2004 I scratch (that means building without an assembling set) Formula 1 and sportscars in 1:10th scale. The average time I need for such a car is around 400 to 700 hours within 4 to 8 months. One car has around 3500 up to 5000 single components. On this blog, you can take a look on my work and later, after my studies, hopefully you can see me in Formula 1.

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