B.Sc Thesis| CHASSIS
The manufacturing process from a CAD model to a driveable car through some insight into various design and fabrication stages.
The standard procedure for the creation of most parts, started with a CAD model that was later laser cut, press bent and-/or Tig welded accordingly.
Manufacturing methods used include:
Lathe milling, CNC machining, Laser cutting, Press-brake bending, MIG-/TIG welding.
The metals that were used include St37 up to St52 steel, 304 stainless steel,
1050-/5083-/6061-/7075 Aluminium.
MDF jig puzzle after laser cutting
Real dimension tube templates, printed on A0 paper
Testing to determine optimum chassis tubing chamfer and amperage for TIG welding
View of the chassis and front lower chassis box inside the jig. Laser cut MDF was choosed for the fixtures due to cost and ease of assembly. Given that this is a self founded prototype project, a steel fixture was not a choice.This knowingly didn't provide optimum stiffness to the Jig, so the fixture tolerances were kept tight and the chassis was completed in steps incorporating specific welding methods to keep it straight as possible. The end result proved to be really good in terms of accuracy.
Near to finish chassis and engine fitment test
Some of the laser cut parts that were welded on the chassis like suspension mounts, adjustable steering column, fuel rail supports and braces. Material: S355JR Steel
Adjustable steering column and engine mounts. Laser cut S355JR steel,
press-brake bent and welded to the chassis
Incomplete Chassis (left) and complete Chassis before being powder coated (right)
The bottom of the car is completely flat using both fixed and removable laser
cut aluminium panels for service and modification purposes
Assembly of panel and heat insulation after powder coating.
5083 laser cut Aluminium hand-brake lever and 1050 aluminium dash
Engine and dash wiring repair with help from the S2000 workshop manual
304 Stainless exhaust fabrication with stainless flange and 2x O2-EGT sensors
Rear view of suspension, differential mounts and diffuser
