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.
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.
The WordPress.com stats helper monkeys prepared a 2014 annual report for my blog.
A special year ends for me. The obvious highlight was working at Red Bull Technology, a lifetime dream got true! This experience ended up in our special vid which was produced by Siemens in cooperation with RBT. Click here to watch. In meantime I am back on uni finishing my studies in MechEng before returning to Formula 1.
In terms of building my paper cars, it was a bit more quiet than the years before. There was some progress on my Lotus, however I’m working now over 16 month on this car. The famous RB7 took me just 12 month. But there’s some light at the end of the tunnel: I expect to finish the E21 in summer.
Last but not least, my FB page has now more followers than my native village has inhabitants (that’s actually not that difficult, as we have just a bit less than 1300 inhabitants 😀 ).
Anyway, I want to greet all of my fans with this and wish you a happy new year and you’ll read from me in 2015.
Here’s an excerpt:
The Louvre Museum has 8.5 million visitors per year. This blog was viewed about 180,000 times in 2014. If it were an exhibit at the Louvre Museum, it would take about 8 days for that many people to see it.
A bit belated, but finally this great video, which resulted from the great work of Video Director David Betteridge in cooperation with Siemens and Red Bull Racing, shows my rise from a simple model builder to a proper Formula 1 car designer.
I just want to say a huge thank you to all the people who supported me on my way into Formula 1. Enjoy!
Chassis finishing off
As reported in the last post, the chassis was in the paint process over the last few days. This car is the first one, where I created a really planed paint process. There were four steps:
- 1st Step, paint preparation: Sanding every single surface of the car and especially cutting edges up to 1500 sand paper. After sanding, all sponsor labels were added as quick as possible to avoid damage or whitening. Quick clean of the main surfaces to get rid of big dust particles or similar contamination.
- 2nd Step, prime coat: Tape all surfaces that need no highly polished surfaces (means monocoque inside, chassis sides behind side pod intake). Applying first coat of clear lacquer immediately after finishing with the first step. Applying 9 layers at all. Waiting at least half an hour between applying next layer.
- 3rd Step, main coat: Add all missing non highly polished surfaces to the chassis (monocoque underside, front bulkhead, radiator ducts,…). Applying additional five coats of clear lacquer and drying it on a radiator. Waiting at least one hour between every single coat.
- 4th Step, subsequent improvement: Inspect painted surfaces and apply another few spray dots to faces where no polished finish yet.
And the result of this process is astonishing! I never got such a nice surface quality and highly polished finish of the car. I will apply this process from now on at every car with probably a few improvements.
After the paint process it’s obviousely very critical to work on the car (avoiding surface containment). When I’m working on a specific area on the car, I have to cover the surrounding surfaces with some tape stripes. What I also detected during working on the car shortly before the paint process is, that the monocoque is fucking extremely stiff and rigid. I was hardly struggling to get the holes for mirror assembly and nose pins done. With a hammer and a scriber and nail I was working for several minutes to get this four holes onto the car. That means, that the implementation of my thoughts about how to get the chassis stiffer and not significantely heavier has taken full effect. I guess I was never so satisfied with a chassis as I am at the mo. Although there could be some minor improvements, but that can wait till the next car.
During the paint process, which contains a lot of waiting (which I partly bridged by drinking beer), I also started the manufacturing of the engine. The manufacturing of the engine block is one of the most annoying parts of the car. Machined metal parts, the most time consuming work in paper modelling. It’s a pain in the ass!
Here are just some pictures to show you the incredible surface finish of the car:
Chassis ready for Paint Shop
Just a short, but reasonable update. Chassis is now finished for 1st stage painting! During paint process I’ll start off with the engine.