Hi Folks,
if you want to, you can take a look at photos which we are taking while we are welding our frame. The archive is updated every 2-3 days. I hope you enjoy the show.

http://www.flickr.com/gp/23543277@N07/207n9q

Regards,

Tobias

"A" for manufacturing process. I love that jig table!

I think we have the same fixturing table.

It is so nice fabricating with real fixtures.

Thanks,
the whole team is looking forward to the engagement between engine and frame next week. We will then continue to post pitures in the album.

Regards,

Tobi

I noticed you have used Catia to design your chassis, how did you go about profiling the ends of the tubes so they fit together ?

quote:

Catia to design your chassis, how did you go about profiling the ends of the tubes so they fit together ?

We have a Masterpart in which all important geometries and interfaces are defined. This Masterpart contains a wireframe of the frame. The frame it self consists out of different Parts, a Masterpart for the frame and a part for every single tube. The Masterpart for the frame includes the wireframe as a linked result and it defines all bisecting planes of the angle between two tubes. In the tubeparts we design the tubes. A tubepart includes as well its referenz line and the bisecting planes ,which are required to cut the tube in shape, as linked results.

Tubes with different outer diameter do not fit together using bisecting planes. In this case we link two tubeparts together and use geometric operations to fit the tubes together.

We had a little trouble to get the links to work and not to generate loops, but in its third evolution our CAD structure works fine.

Thanks for that. I have been using GSD and the Join/trim function for profiling the ends of the tubes, but it won't let me close the chassis. For example if I want to join the seatbelt bar to the roll hoop, you can only profile one end, as the seatbelt bar becomes part of the rollhoop on the first operation.

looks good guys. that jig table is sweet.


http://www.flickr.com/photos/lionsracing/2262914188/in/set-72157603863531783/
mullet?

quote:

http://www.flickr.com/photos/lionsracing/2262914188/in/set-72157603863531783/
mullet?

This is me. Looks funny on this picture, but I think the effect is caused by the jacket ;o)

quote:

Originally posted by Chris_S:
Thanks for that. I have been using GSD and the Join/trim function for profiling the ends of the tubes, but it won't let me close the chassis. For example if I want to join the seatbelt bar to the roll hoop, you can only profile one end, as the seatbelt bar becomes part of the rollhoop on the first operation.

Hi Chris,

i knew this problem from our LR06. We designed the frame in one Part as well. At that time we solved the problem by duplicating every tube several times and using only these doubles in the Boolean operations. Today i would suggest to use paste special with result as link instead of paste. In 2006 it took us several hours to change a wall thnickness.

I hope it helps.

We've used Solidworks this year for the chassis, which has a nice tube joining function in the weldments section. Given that Dassault Systems bought Solidworks, its odd that they've not included it, maybe its included in the higher level versions.

Thanks for the help. When is the first run of the car scheduled? Were hoping to get our car running in the next few weeks.

Hey Chris,
we plan to have it rolling on the beginning of April. Depends mainly on the last stage of the frame building as we are waiting for our butt straps at the moment.

Where is your team from? (England, yes, but where in England?)

Regards,

Tobi

I'm from Hertfordshire, UH Racing.

Hey folks,
we have new pictures online. The engine was placed inside the frame and we have also made some pictures of our wishbone jig.

Regards,

Tobi

Hey guys,
I just want to mention that we migrated our photo gallery from Flickr to our homepage. From now on, you will find our pictures at http://www.lionsracing.de/component/option,com_ponygall...ry/catid,83/lang,de/

I am still transferring pictures and we will continue to update the gallery every 2 or 3 days, so check back regularly if you are interested in our progress.

Regards,

Tobi

are your chassis tubes milled?

Nope,
they are laser cutted.

Regards,
Tobi

even nicer....wow....

must be nice to just have to weld it together...we are still stuck with manual prepping....

Again some new pictures since we began to assemble the LR08: www.lionsracing.de/photos

@RacingManiac: Yes, it helps a lot and as you can see on the pictures, they usually fit well. We are very happy to have a sponsor doing this for us.

Regards,

Tobi

Laser cutting is not all it's cracked up to be. There is a good .010" per foot tolerance on the cuts, with even more deviation on thick bars. So really you can't use laser cutting for the hardpoints, diff mounts, etc. But for the side impact structure, bulkhead, etc. it's a godsend.