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Recent
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cravenju
October 13, 2017
174
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2017/10/14 15:59:48
35177
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2017/10/14 15:59:49
35177
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2017/10/14 15:59:50
35177
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2017/10/14 15:59:51
35177
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2017/10/14 15:59:52
35177
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2017/10/14 15:59:53
35177
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2017/10/14 15:59:54
35177
Base Cage designs with multiple additional members to test effectiveness.
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2017/10/14 18:02:59
35177
Results of 7g Vertical load on driverβs corner
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2017/10/14 18:03:52
35177
7g Vertical load on driverβs corner for comparison to other designs
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2017/10/14 18:04:12
35177
Torsional load on middle and rear mounting points for comparison to other designs
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2017/10/14 18:04:13
35177
Results of Torsional load on middle and rear mounting points
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2017/10/14 18:04:14
35177
Main Hoop Vertical Load (lbf) πΉ=7.5βπ πβπππ, π=ππππβπ‘ ππ πΆππ+150ππ Max Stress = 32.6ksi
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2017/10/14 18:04:15
35177
Rate of Deceleration (ft/s2) π_π^2=π_π^2+2ππ₯ 15mph rear impact with tire wall β Max Stress = 31.8ksi
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2017/10/14 18:04:16
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2017/10/14 18:21:42
35177
BOM of the final cage design. I plan on releasing these drawings some time in the future.
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2017/10/15 14:31:19
35177
Making our first bend with the JD Squared Model 3 bender. Centerline radius is 4.5" to meet the minimum requirement of 3xOD.
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2017/10/15 14:32:10
35177
Main hoop, forward hoops, front bars, and some underbody braces bent.
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2017/10/15 14:32:11
35177
I can't tell you how satisfying it is to bend DOM tubing. See that dark gray Downdraft filter box to my right? Keep an eye on that.
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2017/10/15 14:32:12
35177
Plasma cut some 0.25" plates out for the mounting plates, rear sub/shock tower bracing, and front tower bracing. Only ~ 0.080" is required, but our data proved thicker plates would eliminate some of the tower flex in the front after removing the wheel wells completely.
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2017/10/15 14:32:13
35177
Test fitting my plate - that cutout on the right side is for the stock fuel tank inlet cover.
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2017/10/15 14:32:14
35177
First ever weld with DOM tubing. I am an Engineer, not a professional, but we did test our weld penetration and with a little more practice, the minor undercutting was eliminated. Also, using a ~$2500 tig setup helps.
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2017/10/15 14:32:15
35177
Welding plates to the body with a harbor freight flux core welder.
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2017/10/15 14:32:16
35177
Looking nice and clean.
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2017/10/15 14:32:18
35177
My welding skills ~ 7/10 Kyle and Morgans tube coping skills > 9,000
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2017/10/15 14:32:20
35177
Test fitting our dash over the dash bar, overhead clearance, and harness angle and seat clearance for the harness bar.
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2017/10/15 14:32:21
35177
Front angle of the cage. We aren't running any type of hood, so something needs to be done with the cowl area...
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2017/10/15 14:32:22
35177
Putting that Downdraft filter case to use! The little stitch welds were only used to save wire and time - they also match the seam welds that morgan tacked all around the car.
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2017/10/15 14:32:23
35177
Got really lucky with the position of the dash bar for the steering column. We were unsure if we could get it perfect, but we did.
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2017/10/15 14:32:24
35177
Bill of materials all ready to go.
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2017/10/15 14:53:32
35177
Main hoop, forward hoops, front bumper bars, and some under body braces made.
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2017/10/15 14:53:34
35177
I cannot begin to explain how satisfying this was to do. That big gray box to my right is a Downdraft Filter Case. Keep an eye on that.
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2017/10/15 14:53:35
35177
Plasma cut mounting plates out of 0.25" plate. Only 0.080" was required, but with all of the removed material and a little FEA, we decided to overkill these plates to increase the stiffness of the tub.
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2017/10/15 14:53:36
35177
Rear mounting plates turned out fantastic. The cutout is for the fuel tank cover and the little holes are perfectly cut to allow us to weld the subframe studs to the plate.
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2017/10/15 14:53:37
35177
First EVER DOM weld, here. Minor undercutting, but I'm an Engineer, not a Welder - A little more practice and they were much better. Having a sychrowave definitely helped...
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2017/10/15 14:53:38
35177
Close up of the flux-core weld on the mounting plates. Harbor Freight FTW!
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2017/10/15 14:53:39
35177
I had to get creative with my cup/tungsten choices here and do a lot of upside down welding. None of that was half as bad as having to cope all of these tubes. Kyle and Morgan kicked a** on that.
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2017/10/15 14:53:40
35177
Cage nearly finished. Test fitting the dash over the dash bar and preparing to make the harness bar around the seat.
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2017/10/15 14:53:41
35177
Front view. We aren't going to have a hood, obviously, so we'll need to do something about the cowl area.
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2017/10/15 14:53:42
35177
Cue: Downdraft Filter Case. The sheet metal work as literally tacked on to match the styling of the stitch welds that morgan laid on every seam on the car.
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2017/10/15 14:53:43
35177
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