Vehicle Status 2011

[BMH]

Well I have not seen one of these threads yet for 2011, so I figured I'd start one.

[wagemd]

Originally posted by BMH:
Well I have not seen one of these threads yet for 2011, so I figured I'd start one.

Upperclassmen have been busy with design work, but we dont start class for another week and a half (Sept 29) up here in the NW. New members wont start to roll in until around then as well...

[Dash]

Missisippi State University is well into the design phase. Trying to round up some money so we can start buying parts and get the ball rolling.

[Mikey Antonakakis]

Columbia is well ahead of last year's schedule, chassis is locked, suspension is pretty much locked, powertrain is fairly far along. We're keeping a lot of things that worked well last year similar this year in an effort to save time and keep it simple. If we keep up the momentum we will finally have a car done months before competition instead of at competition. Now it's time to start focusing on the smaller things, like fuel, cooling, etc. And we have a LOT of interest in the club this year. We grew from about 10-15 memebers in 09 to around 30 last year, and we have a lot of returning members with a dozens of highly interested new people. Our work is cut out for us in keeping those new guys around by keeping them busy and getting them involved. Looks like my senior year is going to be a good one, I'm very excited.

[Homemade WRX]

I managed to swing by ODU's motorsports lab this week. Last year the majority of the team was seniors but were unable to finish the car (for various reasons)...so this year, lots of new guys with a incomplete car and picking up the puzzle pieces. Should be interesting for them and a very steep learning curve.

[RollingCamel]

Can't get a team running without a faculty adviser. Until then there is no AUMotorsports.

[AxelRipper]

Chassis design is nearly finished. We proved this past weekend at UoT that we can indeed run on EFI. Some of the chassis is started, but not much. End of our summer term here, so hopefully within the next few weeks (beginning of next term) things will be getting started up.

[RobbyObby]

Chassis design is (for the most part) finished. Just a few tweaks with rear packaging. Waiting on our metal order to begin fabrication.
Powertrain systems are being designed, and we're still trying to source our engine before we can start testing systems.
We are pushing our efforts with aero and composites this year, and they are currently throwing together designs for small scale wind tunnel tests.
We are also making the switch to 10s this year so the wheel package is being redesigned and FEAed.
Lots of exciting developments in the works! I cant wait until it all comes together!

[sbrenaman]

Kinematics and rules compliance verification going on here. Should have a first design iteration in 3 weeks.

[Dsenechal]

Frame design done and FEA'd, Suspension geometry finished minus tweaking front and rear ARB's. Wheel centers designed and ready for machine shop. Design going on for the uprights, stubshafts, diff carriers, etc...

Hoping to start ordering steel here in the next two weeks or so, and get this puppy rolling

[Rotary Sprocket]

Started our frame last week. Waiting for our roll hoops to get delivered and then we'll finish building the rest of the front half. Suspension geometry is done just designing components now. All we need is money and stock so we can start machining parts.

[Andrew07]

Originally posted by Rotary Sprocket:
All we need is money and parts

This made me lol.

[JasperC]

Our new team has started conceptual design on part-level. The overall concept of the car is that it will be electric, and it will be something with two motors.

(This also means that the DUT10 was the last combustion car from Delft.)

Regards,
Jasper Coosemans
DUT Racing Team 2008-2010

[blister]

Jasper,

I am really excited to hear that from your team! We are also in a conceptual stage, altough we have still one race ahead.

Two motors is also our concept. Hopefully your car is not 50kg lighter than ours like in the ICE Age :-)

[StephenAero]

Here's what our aero lead came up with after the new rules came out.

http://img405.imageshack.us/img405/3783/hahaplane.png

Quite frankly though, we're all skeptical.

[Chris Texas]

Our much much smaller 2011 frame. Almost done with all the tubes. We just have to place the engine, add shock mounts, and front bell-cranks tabs. We're hoping to get sprung by winter break. How's everyone else coming along?

Chris
Team Captain
Longhornracing.com
University of Texas Formula SAE

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1121.snc4/148389_10100375327223110_7963038_65871721_4353123_ n.jpg

[coastertrav]

It's amazing how alike all the chassis end up looking (for the most part).

[Mikey Antonakakis]

We started the day with a box of tubes, and by the end of the day had everything but engine mounts tacked together.

[Joe17]

http://i160.photobucket.com/albums/t186/sprtcrazy17/185338565.jpg

[Wetmelon]

We're well on our way into design. I doubt we'll start tacking the chassis until... either just prior to or post Christmas break. Not on that squad, though, so I'm not terribly certain. Electrical is WAYYYYY ahead of schedule relative to last year.

When do your cars usually get finished? Last year ours was complete a couple weeks before comp :P

[AxelRipper]

we have some tubes bent, others cut, some welded together. aaand thats all i'm allowed to say right now

[Chris Texas]

We're hoping to get our car driving by February. We spent all summer designing, which helped, a lot.

Chris
Team Captain
longhornracing.com
The University of Texas Formula SAE

[Dsenechal]

Thanksgiving update anybody?

[DEAD_MAN]

Have taken a semi-break coz exams are at the door step......
behind our own schedule...final assembly on CAD still left...
Hoping to finish the assembly as soon as the exams get over ie last week of December...
Go ORION RACING INDIA

[Mumpitz]

Only break here was to fix a busted heater hose on my girlfriends dad's car then go back to cleaning up the wiring on the dyno.
It's 2 AM and there are still 4 of us here at the garage. Catching some sleep to hit it hard again in the morning. It's been a few months since I've crashed on the couch at the garage...
The hard work from all of the team has really been paying off; I don't think any formula team will ever know what the term "ahead" feels like but this doesn't feel like we're behind.
It's on like Donkey Kong!!!

[JasperC]

Delft had their design presentation yesterday: youtube.com/watch?v=-MpQi82ZW2M

I think the guys have done a good job so far. http://fsae.com/groupee_common/emoticons/icon_smile.gif

Best regards,
Jasper Coosemans
DUT Racing Team 2008-2010

[Thrainer]

Indeed, it looks pretty good. I'm just wondering about this huge electronics box, where the cooling air gets out after the radiator and how you can put the accumulator containment into the car. Is that the first year you are using a steering system like that (cables instead of gears)?

Looking at the uprights and hubs, you have definitely left the path of "gokart design" a bit. What is your weight target for the car?

Regards,
Thomas

[DMuusers]

The accumulators can go out through the seatplate, so that shouldn't be a problem. Yes, it's the first time we're doing that system. It's our take on steer-by-wire. The weight target is 180 kg.

How is everything going with your car Thomas? Can we expect a design presentation shortly?

[KyleD]

We just got our chassis tubes back from laser cutting last week, front bulkhead and front roll hoop are tacked up. Chassis jigs are nearly complete and we're going to get a main roll hoop bent sometime in the next few days. We're hoping to have a chassis complete over winter break.

[blister]

Very impressive Video Delft, mainly the posting date ;-)

We hope to be at the same level of process in late January. We have many new students that had first to grow into the project.

My biggest fear is that our car will be white like last year and not BLACK like 2009.

cheers

[TMichaels]

Yes, it's the first time we're doing that system. It's our take on steer-by-wire.

You should definetely check back with Ulf Steinfurth, if this solution will be allowed during scrutineering as I have seen similar systems being rejected.

Regards,

Tobias

[DMuusers]

The thing is though that it IS a mechanical connection and since the rules intent is towards an electrical connection, our solution should be allowed. But yes, we should better check with the competitions to see what they think about it.

[Luniz]

Our 2006 vehicle featured a drive belt in the steering system and it has been rejected... So you better check that beforehand

[The AFX Master]

Isn´t a steel cable inherently far less stiff than tubing??, why should place such compliances on steering?. And supposed it´s right on the stiffness department, how about weight?

[DMuusers]

It isn't a steel cable, it's a special kind of fibre. I don't know the full details about it since I did the spring damper system, but I know that it'll work. http://fsae.com/groupee_common/emoticons/icon_wink.gif

[The AFX Master]

Nice stuff then. http://fsae.com/groupee_common/emoticons/icon_biggrin.gif

[PatClarke]

Hi Daniel,

I see an opportunity to make a little money here ;-)

Wanna bet your cable steering WILL be accepted at Tech?

Pat

[Ben K]

NFR has a a good portion of our frame welded together now. Should be finishing it off in the next few days. With a bit of luck we'll be done in no time....

Ben

[The Egyptian]

Hi every one i'm really happy to join, our team from Helwan University in Cairo,Egypt is in for the second year.
I hope the best of luck for every body.

we started the design and we have almost finished , we just on hold because the semester's exams.
Ayman
Frame Team Leader

[KyleD]

Here's a picture of our chassis so far. Every major tube is in except main roll hoop bracing and a few other minor tubes like shoulder harness mounting, etc. Yes, there is an inherent lack of triangulation in the whole front section but structural bonded panels are soon to come.
http://i1214.photobucket.com/albums/cc484/kdson25/Formula%202010-2011/chassisforum.jpg
This is the engine placement in the rear, packaging is going to be super tight, but I wouldn't have it any other way http://fsae.com/groupee_common/emoticons/icon_smile.gif
http://i1214.photobucket.com/albums/cc484/kdson25/Formula%202010-2011/engine.jpg

[Austin B]

Follow us in Facebook to see!
http://www.facebook.com/pages/...2099461500458?ref=ts (http://www.facebook.com/pages/Oxford-Brookes-Racing/152099461500458?ref=ts)

[rDynamic5]

It's not going very fast at this point, but at least the car is moving.

Missouri S&T's first drive: youtube.com/watch?v=H1oGIjHKiqI

[Mike Cook]

Sweet....congrats.

[Terriblewone]

We are pretty close to a rolling chassis. Here are some detailed shots from the other day I took at the shop.

http://www.flickr.com/photos/29414553@N02/

http://farm6.static.flickr.com/5011/5462922031_c527eebc98_b.jpg

http://farm6.static.flickr.com/5216/5463522350_cf95414f94_b.jpg

http://farm6.static.flickr.com/5018/5463521052_1988869817_b.jpg

http://farm6.static.flickr.com/5054/5463519904_87b7b9c529_b.jpg [/quote]


Here is one of the chassis that jon took a week ago.
http://farm6.static.flickr.com/5018/5445766742_2021e2ae1d_z.jpg
Jon's Flickr:
http://www.flickr.com/photos/joncalvert/

[Thrainer]

We have published a newsletter about our 2011 concept: http://www.amzracing.ch/amz/files/amz1825.pdf

Highlights include one-piece CFRP prepreg monocoque, selfmade brushless motors, selfmade gearbox, CFRP driveshafts.

Regards,
Thomas

[Thrainer]

Just letting you know that some posts with URLs have been approved.

I'm looking forward to reading your comments on our newsletter.

[Mazur]

Originally posted by Terriblewone:
We are pretty close to a rolling chassis. Here are some detailed shots from the other day I took at the shop.



Just curious, what sheetmetal thickness are you using? The pic makes them look pretty beefy.

My team is using 20 gauge (.036'') 4130 sheet.

[Goost]

Ran this morning.
War Eagle

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/182953_205096582837551_176332719047271_882150_6639 139_n.jpg

[Pennyman]

Nice tunnels http://fsae.com/groupee_common/emoticons/icon_smile.gif

[SupraSteve]

Mazur,

I can respond with regards to sheetmetal thickness.

It's .050" 4130 sheet. The FOS is ridiculous, but the team has had a major design changover this year; first time 10" tires, single cylinder, susp kinematics and sheetmetal uprights, all aluminum diff.

sooooo many changes we decided to play it safe in most areas with the goal of finishing endurance. We are hoping for further optimization once we see how all the new systems are operating.

thinner upright material is one of those things for next year. strain gauges should help with that. Key concern was to get the manufacturing process down, including the fixture design. So far so good. We'll see when the car turns a wheel...

[Terriblewone]

Originally posted by Mazur:
<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by Terriblewone:
We are pretty close to a rolling chassis. Here are some detailed shots from the other day I took at the shop.



Just curious, what sheetmetal thickness are you using? The pic makes them look pretty beefy.

My team is using 20 gauge (.036'') 4130 sheet. </div></BLOCKQUOTE>

0.035" 4130 on the control arms

edit: refer to Steve's post for the sheet metal in the uprights.

[rDynamic5]

Originally posted by Thrainer:
We have published a newsletter about our 2011 concept: http://www.amzracing.ch/amz/files/amz1825.pdf

Highlights include one-piece CFRP prepreg monocoque, selfmade brushless motors, selfmade gearbox, CFRP driveshafts.

Regards,
Thomas

That is a great looking newsletter. The car also looks like it will have a lot of potential if the team can getting everything working well and reliably.

[ZAMR]

I wonder how many teams are going to show up with gigantic diffusers.

[Terriblewone]

Steering is in
http://farm6.static.flickr.com/5092/5486429671_46e1cd65e1_b.jpg

Some goodies came in the mail!
http://farm6.static.flickr.com/5095/5478066304_c9dc2b2ef7_b.jpg

[coastertrav]

I think you've severely underestimated the amount of force that your steering mount is going to see.

Also, have any pictures of your setup (white box, lighting, ect)?

[Goost]

http: / / www . facebook . com / pages / Auburn-University-Formula-SAE-Racing-Team / 176332719047271

[Terriblewone]

In terms of steering rack mount, its not my department, but I am pretty sure the same style of hardware and mounts were used on the previous three cars.

In terms of light box/setup, its far less complicated than it looks. I just spent 2$ on white poster board. I have a key light that is a SB800 shot into a white umbrella from above at a 45 pointing down and then I use my other strobe as fill by bouncing it off of the ceiling above that happens to be white. Sometimes the easiest solution is a decent one. It saves me from having to setup a lot of gear at the shop. Anyways let me see if I have a photo on my car of the setup...

[RANeff]

Shitty phone pic:

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/183670_10150104010493848_184988848847_6496008_3504 338_n.jpg

set-up for first drive

[DEAD_MAN]

Work going on in FULL FORCE...!!!
The whole chassis welded in a span of 3days and 8 hrs....thnks to our Chassis team...!!!

http://img145.imageshack.us/i/photo0645.jpg/

http://img864.imageshack.us/i/photo0646.jpg/

[DEAD_MAN]

Work going on in FULL FORCE...!!!
http://img864.imageshack.us/i/photo0646.jpg/

http://img145.imageshack.us/i/photo0645.jpg/

[cwatson]

In the end, I persuaded the chassis guys the preliminary aero design was the way to go:

http://img405.imageshack.us/img405/3783/hahaplane.png

After 5 months of build, it's done!

http://img855.imageshack.us/img855/931/marylandaero.jpg

Yes.

[terps racer]

that thing is SWEET!

[Crispy]

What made you go with the twin over the four? http://fsae.com/groupee_common/emoticons/icon_smile.gif

[Terriblewone]

Steve brought me some shiny stuff today...
http://farm6.static.flickr.com/5015/5524322975_a39dc9dfd0_z.jpg
http://www.flickr.com/photos/29414553@N02/5524322975/

[Rotary Sprocket]

Picture from our second day of testing.

http://www.facebook.com/profile.php?ref=profile&id=1530708394#!/photo.php?fbid=752214095152&set=a.752214040262.2283986.39117534&theater

h t tp:/ /www.facebook.com/profile.php?ref=profile&id=1530708394#!/photo.php?fbid=752214095152&set=a.752214040262.2283986.39117534&theater

[JasperC]

I read about Ann Arbor's car presentation today: fwix.com/annarbor/share/d5e0cc373d/mracing_formula_sae_team_unveils_new_car_for_augus t_competition

Looking good on that pic. Impressive presentation date as well, by the way.

At the end of the article, it reads: "Engineering junior Chris Bury, who manages the car’s breaks, [...]"

Let's hope he doesn't get too much to do then. http://fsae.com/groupee_common/emoticons/icon_wink.gif

Cheers,
Jasper

[cebury]

Yep, it's a great position!

But seriously... total misquote... "we changed our systems a bit" ???

And I have no idea where the weight quote came from.

[Dsenechal]

http://www.youtube.com/watch?v=La4M4vzyhx0

[Markus]

Seems like Stuttgart's got some tubes in, "work in progress":

Youtube: /watch?v=pcMbYGq4N4k

[Pennyman]

Originally posted by Mager:
Seems like Stuttgart's got some tubes in, "work in progress":

Youtube: /watch?v=pcMbYGq4N4k

That would be Helsenki Polytechnic in fact. One guy is just wearing the infamous Rennteam shirt http://fsae.com/groupee_common/emoticons/icon_smile.gif

[Thrainer]

The first prototype of our selfmade electric motors is running on the test bench.

youtube dot com /watch?v=Z6oZQUhATfE

Machining aluminium parts and laminating carbon prepreg parts are in full swing.

[DEAD_MAN]

http://img14.imageshack.us/i/ori11.jpg/

ORI 2011 - 'Aeton' is now ready to roar...

[Thrainer]

Good to read that GFR is going with carbon look this year. I like your steering gear, looks very light. Did you guys use the same moulds for the monocoque as last year? That would make four cars from one mould, impressive.

We've made a video of our crash nose testing

youtube dot com /watch?v=rirjrXm1j98

Regards
Thomas

[Tom W]

Does that IA fail by forming distinct plastic hinges or do you still get a continuous progressive failure even with such steeply angled side sections?

Awesome video though, I certainly watched the old one you guys had plenty of times!

[Thrainer]

Thanks Tom. I assume you are asking about the CFRP shell nose. I would say both. Some faces are not capable of absorbing energy efficiently, they are kept very thin and simply swivel away. Other faces are strategically strengthened and literally turn into dust while absorbing the impact energy.

The other models using foam are mostly failures themselves.

Regards
Thomas

[StevenWebb]

our chassis construction..

believe it or not this is in slow motion

http://www.youtube.com/watch?v=A1QFe33qIik&

[wagemd]

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/215708_10100360510835298_10742254_55999974_6115697 _n.jpg

Just got the new engine mounted in the chassis: UW FSAE now powered by RedBull!

[DEAD_MAN]

Orion Racing India Unveils its latest creation...
ORI2011 - 'THE AETON'

http : / / img14 . imageshack dot us/ i / ori11 . jpg/

[Jersey Tom]

Originally posted by Terriblewone:
http://farm6.static.flickr.com/5018/5463521052_1988869817_b.jpg

Oh boy. I'd look into buying a bullnose end mill and save yourself the trouble of having to pocket things out with a ball end mill and a zillion passes.

[Terriblewone]

Our car ran yesterday but here are a few pictures from before we assembled the car.

http://farm6.static.flickr.com/5179/5566247125_29fcb62b24_z.jpg
http://www.flickr.com/photos/2...47125/in/photostream (http://www.flickr.com/photos/29414553@N02/5566247125/in/photostream)

http://farm6.static.flickr.com/5099/5566246031_5cba4b7262_z.jpg
http://www.flickr.com/photos/2...46031/in/photostream (http://www.flickr.com/photos/29414553@N02/5566246031/in/photostream)

http://farm6.static.flickr.com/5136/5566823408_d9c2199c12_z.jpg
http://www.flickr.com/photos/2...23408/in/photostream (http://www.flickr.com/photos/29414553@N02/5566823408/in/photostream)

http://farm6.static.flickr.com/5132/5566822542_624a1952e2_z.jpg
http://www.flickr.com/photos/2...22542/in/photostream (http://www.flickr.com/photos/29414553@N02/5566822542/in/photostream)

http://farm6.static.flickr.com/5257/5544719790_b051a1e452_z.jpg
http://www.flickr.com/photos/2...19790/in/photostream (http://www.flickr.com/photos/29414553@N02/5544719790/in/photostream)

http://farm6.static.flickr.com/5095/5544141781_418b649b0a_z.jpg
http://www.flickr.com/photos/2...41781/in/photostream (http://www.flickr.com/photos/29414553@N02/5544141781/in/photostream)

http://farm6.static.flickr.com/5070/5566850834_068b98fcdd_z.jpg
http://www.flickr.com/photos/5...50834/in/photostream (http://www.flickr.com/photos/57197772@N07/5566850834/in/photostream)

http://farm6.static.flickr.com/5052/5566270741_1983a5a2eb_z.jpg
http://www.flickr.com/photos/5...70741/in/photostream (http://www.flickr.com/photos/57197772@N07/5566270741/in/photostream)

http://farm6.static.flickr.com/5297/5566268907_4e593c7f71_z.jpg
http://www.flickr.com/photos/5...68907/in/photostream (http://www.flickr.com/photos/57197772@N07/5566268907/in/photostream)

http://farm6.static.flickr.com/5140/5544177041_9a4787d11a_z.jpg
http://www.flickr.com/photos/5...77041/in/photostream (http://www.flickr.com/photos/57197772@N07/5544177041/in/photostream)

http://farm6.static.flickr.com/5055/5536296884_56c643952b_z.jpg
http://www.flickr.com/photos/5...96884/in/photostream (http://www.flickr.com/photos/57197772@N07/5536296884/in/photostream)

http://farm6.static.flickr.com/5054/5535717957_76463704dc_z.jpg
http://www.flickr.com/photos/5...17957/in/photostream (http://www.flickr.com/photos/57197772@N07/5535717957/in/photostream)

http://farm6.static.flickr.com/5053/5544713628_4f34c17e96_z.jpg
http://www.flickr.com/photos/2...13628/in/photostream (http://www.flickr.com/photos/29414553@N02/5544713628/in/photostream)

[Terriblewone]

http://farm6.static.flickr.com/5107/5666938056_2b93318aef_z.jpg
http://www.flickr.com/photos/2...38056/in/photostream (http://www.flickr.com/photos/29414553@N02/5666938056/in/photostream)

http://farm6.static.flickr.com/5303/5666359883_6b2a811490_z.jpg
http://www.flickr.com/photos/2...59883/in/photostream (http://www.flickr.com/photos/29414553@N02/5666359883/in/photostream)

http://farm6.static.flickr.com/5145/5666355685_b59d70429d_z.jpg
http://www.flickr.com/photos/2...5685/in/photostream/ (http://www.flickr.com/photos/29414553@N02/5666355685/in/photostream/)

http://farm6.static.flickr.com/5106/5666349801_4fdb9b4eb0_z.jpg
http://www.flickr.com/photos/2...49801/in/photostream (http://www.flickr.com/photos/29414553@N02/5666349801/in/photostream)

http://farm6.static.flickr.com/5101/5666345989_ce7510dfe0_z.jpg
http://www.flickr.com/photos/2...45989/in/photostream (http://www.flickr.com/photos/29414553@N02/5666345989/in/photostream)

http://farm6.static.flickr.com/5108/5666911496_21f0f396b0_z.jpg
http://www.flickr.com/photos/2...11496/in/photostream (http://www.flickr.com/photos/29414553@N02/5666911496/in/photostream)

http://farm6.static.flickr.com/5228/5666905602_7d27e37c92_z.jpg
http://www.flickr.com/photos/2...05602/in/photostream (http://www.flickr.com/photos/29414553@N02/5666905602/in/photostream)

http://farm6.static.flickr.com/5264/5666900574_253d57bd70_z.jpg
http://www.flickr.com/photos/2...00574/in/photostream (http://www.flickr.com/photos/29414553@N02/5666900574/in/photostream)

http://farm6.static.flickr.com/5068/5666323363_5e26fa49f6_z.jpg
http://www.flickr.com/photos/2...23363/in/photostream (http://www.flickr.com/photos/29414553@N02/5666323363/in/photostream)

http://farm6.static.flickr.com/5183/5666885640_cba21be5da_z.jpg
http://www.flickr.com/photos/2...85640/in/photostream (http://www.flickr.com/photos/29414553@N02/5666885640/in/photostream)

http://farm6.static.flickr.com/5143/5666880690_2ded50ecca_z.jpg
http://www.flickr.com/photos/2...80690/in/photostream (http://www.flickr.com/photos/29414553@N02/5666880690/in/photostream)

[Thrainer]

Wow, those are huge driveshafts, seems about 90 mm diameter. Are the tripod housings glued in directly?


You can follow our progress closely on twitter dot com /amzracing and facebook dot com /amzracing
If there's something you want to see or discuss, feel free to post here.

Regards
Thomas

[Terriblewone]

The tripod housing are turned down a little bit but yes they do reside inside the half shafts (bonded/glued in). I picked one up the other day and I can hardly believe how light they were.

[Matthew Bell]

Wow, that's a very impressive looking setup! Just curious, any idea what kind of heat your muffler puts onto that drive shaft? I don't have any experience with singles, thought it might be an interesting discussion.
Also really liking the dual in-board brakes setup!

[DanielH]

A lot of interesting stuff. so many questions.
What type of U-joint is it. How much does it wobble when you turn the wheel? does it cause any play at the wheel?
Our muffler on our V twin doesn't get to hot. But the muffler is homemade.

[Chris B]

hey all,

UQ Racing (from the university of queensland), had our first track test on the 20th of April. All went well. Should be back on track again soon.

[SupraSteve]

I guys, I designed the drivetrain on the car above...

driveshafts are huge, but thin and light.. reason for the size is so that I could bond the CV joints in directly, with no weird shape changes. forces SHOULD be close to the hand calcs this way...eliminate error from having bolt holes and flanges etc.

They are taylor race tripods joints on both ends. To be honest, I'm not happy with how much play there is....I should have made my own.

the "inverted" layout lets me use a proper intensifier, and all I have to do is make a simple, straight tube.

they were made properly in an autoclave.

Heat doesn't seem too bad right now. the shell of the muffler does a good job of insulating. I now have protective tape on the shafts.

OD is 73mm, driven by the CV joint size.


Daniel, the U-joint is a borgeson, straight up automotive U-joint. We had no idea where to find the smaller U-joints everybody uses. It does wobble, at least in that state. It required a shaft support right on the steering shaft remove it.

The joint type is a DD shaft. Set screws are replaced with safety-wired bolts, but they just keep the joint from shifting. We machined the male DD plug, and welded it to the 5/8" tubing. tight fit, there's no play at all in the U-joint or shaft connections. All the play can be found in the purchased quick release. This style was all new to us this year (last year was our first bottom mount rack). but we are happy with the system. just need a lighter joint now!

[Bcohen5055]

Colorado State just ran a full endurance on Sunday

http://farm6.static.flickr.com/5230/5684347042_7b16eaaced.jpg
http://farm6.static.flickr.com/5223/5683779287_67bc816a9a_z.jpg

[Pete Marsh]

Just a heads up guys, the firewall rule interpretation at FSAE-A last year was WAY more strict than ever before. Due to an accident somewhere I believe.

There is no way they would let that run with so much of the drivers neck and lower helmet exposed to the engine bay.

Pete

[RANeff]

Thanks! We didnt have our engine cover in place for the test, which shields the driver from all liquids and heat.


Originally posted by Pete Marsh:
Just a heads up guys, the firewall rule interpretation at FSAE-A last year was WAY more strict than ever before. Due to an accident somewhere I believe.

There is no way they would let that run with so much of the drivers neck and lower helmet exposed to the engine bay.

Pete

[TMichaels]

The accident happened at FSG2010, see pictures here:

http : / / media. formulastudent. de / FSG10 / Hockenheim / 20100808Sunday / 13295050_RMsCx#1048473473_QUXsW

The fire was under control by the marshalls within seconds and no one got hurt, but it showed what may happen.

Regards,

Tobias

[Edward M. Kasprzak]

We didnt have our engine cover in place for the test, which shields the driver from all liquids and heat.

Never drive your car without full safety equipment.

[AxelRipper]

Originally posted by Edward M. Kasprzak:
<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">We didnt have our engine cover in place for the test, which shields the driver from all liquids and heat.

Never drive your car without full safety equipment. </div></BLOCKQUOTE>

And a fire extinguisher.

And also remember how to get out in 5 seconds.

[RANeff]

Originally posted by AxelRipper:
<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by Edward M. Kasprzak:
<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">We didnt have our engine cover in place for the test, which shields the driver from all liquids and heat.

Never drive your car without full safety equipment. </div></BLOCKQUOTE>


And a fire extinguisher.

And also remember how to get out in 5 seconds. </div></BLOCKQUOTE>

We had fire extinguishers on every corner, a radio in the drivers helmet, and can do egress in ~ 3 seconds. We made sure we had the best preperation for the situation, as the cover is not finished, and a simulation was needed to confirm fuel useage. We really appreciate your guy's concern though, we know it was not optimal.

Honestly, the existing firewall does come up to the bottom of the drivers helmet.

[Canuck Racing]

Originally posted by TMichaels:
The accident happened at FSG2010, see pictures here:

http : / / media. formulastudent. de / FSG10 / Hockenheim / 20100808Sunday / 13295050_RMsCx#1048473473_QUXsW

The fire was under control by the marshalls within seconds and no one got hurt, but it showed what may happen.

Regards,

Tobias

You know, you just don't get that kind of excitement from electrons. http://fsae.com/groupee_common/emoticons/icon_wink.gif

[RobbyObby]

The San Jose State caravan just rolled out of town on our way to a few days of final testing with UW-Madison and Stuttgart before heading to MIS. Looking forward to it and can't wait to be competing in Michigan for the first time since '92. See you all there!

[flavorPacket]

Originally posted by Canuck Racing:

You know, you just don't get that kind of excitement from electrons. http://fsae.com/groupee_common/emoticons/icon_wink.gif

You're right, it's much much worse. When thermal runaway happens, you don't run towards the fire, you run away from it...

[TMichaels]

You're right, it's much much worse. When thermal runaway happens, you don't run towards the fire, you run away from it...

Depends on your experience and equipment.

Regards,

Tobias

[Pennyman]

Originally posted by RobbyObby:
The San Jose State caravan just rolled out of town on our way to a few days of final testing with UW-Madison and Stuttgart before heading to MIS. Looking forward to it and can't wait to be competing in Michigan for the first time since '92. See you all there!

See you on the flip side.

[Thrainer]

We are frequently adding pictures to http://www.facebook.com/amzracing and http://twitter.com/amzracing as we are assembling the car.
Our first of four competitions this year will be Formula Student (Silverstone).

[PBjore]

Video from Official launch of Chalmers Formula Student, CFS11 earlier this week. Otherwise testing is fully in progress for FSUK.

Launch video (http://www.chalmers.se/sv/utbildning/filmer/Sidor/Chalmers-Formula-Student-2011.aspx)

[Thrainer]

Some parts of our self-designed gearbox. It's symmetrical for the independent drive of each wheel with one motor each.

http://www.amzracing.ch/amz/files/amz1892.jpg

The final gear and the tripod housing are joined with an interference form fit to transmit the torque.

http://www.amzracing.ch/amz/files/amz1894.JPG

For size reference, the entire gearbox fits on an A4 size paper.

http://www.amzracing.ch/amz/files/amz1893.JPG

We are frequently adding pictures to http://www.facebook.com/amzracing and http://twitter.com/amzracing as we are preparing for the events.

Regards
Thomas

[DMuusers]

Looks fantastic Thrainer. I also saw that your car is completely finished now, congrats! How much does your gearbox with gears weigh? And how much your car? Looking forward to see it at Silverstone and Hockenheim!

[tingra]

Here is the Sooner Racing Team's pre-Cali Promo.

h t t p :// www. you tube .com/ watch?v=7wozSqFXitY

Thomas Ingram
Sooner Racing Team

[bob.paasch]

Originally posted by tingra:
Here is the Sooner Racing Team's pre-Cali Promo.

h t t p :// www. you tube .com/ watch?v=7wozSqFXitY

Thomas Ingram
Sooner Racing Team

Active aero, cool.

[Ben K]

Originally posted by tingra:
Here is the Sooner Racing Team's pre-Cali Promo.

h t t p :// www. you tube .com/ watch?v=7wozSqFXitY

Thomas Ingram
Sooner Racing Team

The aero is pretty darn cool. Does the flow reattach properly?

Ben

[Bemo]

Awesome! How is it controlled? Manually via switch at the steering wheel? Or is it dependant on steering angle, pedal position, driving speed...?

[Wesley]

Originally posted by tingra:
Here is the Sooner Racing Team's pre-Cali Promo.

h t t p :// www. you tube .com/ watch?v=7wozSqFXitY

Thomas Ingram
Sooner Racing Team

Excellent work, guys!

Boomer Sooner!

[Jay Lawrence]

@Terriblewone from Canada, please correct me if i'm wrong, but it appears that your 5th link on your rear upper a-arms has put a rod-end in bending.

[RobbyObby]

Originally posted by tingra:
Here is the Sooner Racing Team's pre-Cali Promo.

h t t p :// www. you tube .com/ watch?v=7wozSqFXitY

Thomas Ingram
Sooner Racing Team

Very cool!
Only question now is where they will put the DRS zone along the track. http://fsae.com/groupee_common/emoticons/icon_wink.gif

[Lorenzo Pessa]

Originally posted by tingra:
Here is the Sooner Racing Team's pre-Cali Promo.

h t t p :// www. you tube .com/ watch?v=7wozSqFXitY

Thomas Ingram
Sooner Racing Team

Have you some rough data to evaluate the gain you get from driving with and without active aero?

Nice work!

[Yannick]

We had our rollout yesterday at the airport of Zürich. Pictures and news can be found on our facebook page.

Videos of our car are on youtube, user/channel is AMZFormulaStudent.


Originally posted by DMuusers:
Looks fantastic Thrainer. I also saw that your car is completely finished now, congrats! How much does your gearbox with gears weigh? And how much your car? Looking forward to see it at Silverstone and Hockenheim!

The gearbox including the gears weighs 2.9 kg including lots of teflon grease. The car itself has come out lighter than expected =)

I'm very curious about your rollout, hope to see some pictures soon.

This active aero package looks brilliant! I'm interested how much added weight you get from your wings and the electronics?

best regards
Yannick

AMZ Racing

[Thrainer]

Daniel, have you been testing yet? Is the car still under 180 kg? Concerning our car's weight, it's "under 190 kg" (with 13" tyres and 70 kW) at the moment.
I've read that URE and WHZ are starting their testing now. It would be great to get more infos on the other cars.


AMZ racing team at rollout
http://www.amzracing.ch/amz/files/27.jpg

Rear end
http://www.amzracing.ch/amz/files/30.jpg

Time lapse video of the assembly of Novena: http://www.youtube.com/watch?v=XB8KIY6tulw

Video of our first couple test days: http://www.youtube.com/watch?v=AwexqZRIL7w

Regards
Thomas

[DMuusers]

Originally posted by Yannick:
We had our rollout yesterday at the airport of Zürich. Pictures and news can be found on our facebook page.

Videos of our car are on youtube, user/channel is AMZFormulaStudent.

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by DMuusers:
Looks fantastic Thrainer. I also saw that your car is completely finished now, congrats! How much does your gearbox with gears weigh? And how much your car? Looking forward to see it at Silverstone and Hockenheim!

The gearbox including the gears weighs 2.9 kg including lots of teflon grease. The car itself has come out lighter than expected =)

I'm very curious about your rollout, hope to see some pictures soon.

This active aero package looks brilliant! I'm interested how much added weight you get from your wings and the electronics?

best regards
Yannick

AMZ Racing </div></BLOCKQUOTE>

Wow, only 2.9kg! Our roll out is this tuesday so pictures should be on the internet by wednesday. And off course you're all invited to come to Delft!


Originally posted by Thrainer:
Daniel, have you been testing yet? Is the car still under 180 kg? Concerning our car's weight, it's "under 190 kg" (with 13" tyres and 70 kW) at the moment.
I've read that URE and WHZ are starting their testing now. It would be great to get more infos on the other cars.


Regards
Thomas

No we unfortunately haven't been testing yet. The car is nearing completion and as far as I know it's going to be on the weight target. In testing we might even ditch a couple of batteries if we find out we don't need them, but we'll have to see about that.

I personally don't know that much about URE and WHZ since I've been working hard on Vehicle Dynamics, but maybe someone from their teams can enlighten us?

[DMuusers]

Finally the long anticipated Roll Out for the DUT11. Today the latest and fully electric Formula Student car was presented to the public. The presentation started of with the DUT10 giving away a show. The FSG winner then made way for the unveiling of the future; the DUT11.

http :// www. facebook .com/media/set/?set=a.199407923438517.54947.100001079321504

If you'd like any pictures in HD, send me a pm (either here or on facebook) with the link of that picture(s) and your email adress. If you'd like to use the pictures in any sort of media, please contact me first.

Hope you'll enjoy!

[Taylor]

Despite our original intentions, The University of Alabama Fsae team now has our 2012 car mostly ready. This car was designed and built to run this year at Michigan, however mother nature had other plans. About 2 weeks before we were scheduled to leave for Michigan, a tornado came through and destroyed much of Tuscaloosa and the surrounding areas. We were unable to work on our and and lost a lot of time. The silver lining in this is that we are basically one year ahead of schedule for 2012 and hope to get some valuable testing done in the fall.

-Taylor

[rmk36]

Originally posted by Taylor:
Despite our original intentions, The University of Alabama Fsae team now has our 2012 car mostly ready. This car was designed and built to run this year at Michigan, however mother nature had other plans. About 2 weeks before we were scheduled to leave for Michigan, a tornado came through and destroyed much of Tuscaloosa and the surrounding areas. We were unable to work on our and and lost a lot of time. The silver lining in this is that we are basically one year ahead of schedule for 2012 and hope to get some valuable testing done in the fall.

-Taylor

Keep truckin...we'll see you in 2012!

[Jan_Dressler]

Some videos from UAS Karlsruhe's rollout...

The crew:
http://www.youtube.com/watch?v=ScoMLH4x8sQ

Manufacturing...
http://www.youtube.com/watch?v...1hfE&feature=related (http://www.youtube.com/watch?v=IhZq6sp1hfE&feature=related)

Final rollout video (yeah, the guy who made it really had too much time http://fsae.com/groupee_common/emoticons/icon_biggrin.gif ):
http://www.youtube.com/watch?v...qBeU&feature=related (http://www.youtube.com/watch?v=B0_o6tUqBeU&feature=related)

[G.Arce]

We are currently running our new model, the fstec'11.

After the official presentation with one of our main sponsors at the Science Museum of San Sebastián (Eureka), we organized a shakedown test for this last friday.

We are currently one month ahead of our usual schedule, so we are really happy with how things are going. It's great to have time to test, understand the car and improve.

Ander Vilariño, European HillClimb champion and currently NASCAR EuroSeries driver, was going to test our car but we had a mechanical failure. A minor problem, currently being fixed. That's what testing is for! Here you have our onboard. Enjoy it!

fstec'11 on track (http://www.youtube.com/watch?v=Y9R8Lh9PtCM)

[DMuusers]

Today the DUT11 drove her first meters:
http://www.youtube.com/watch?v=5f8ALZT3iAA (http://www)

FSUK, here we come!

[Tickers]

Check out some photos of our launch event on the Brunel Racing Facebook page

https://www.facebook.com/media...1.337531.35177124790 (https://www.facebook.com/media/set/?set=a.10150244881119791.337531.35177124790)

[Thrainer]

Daniel, nice drive. Your motors seem to have a lot of low end torque, so I assume they drop off a lot at higher revs (since the power rating is only about 27 kW)?

How much does she weigh now? Novena is about 104 kg at the moment... without powertrain. She's undergoing another motor upgrade.

Can somebody post results from the ZF Race Camp, especially of the electric cars? I'm curious about Munich's 200 kW car, KA and Greenteam.

Regards,
Thomas

[Bemo]

I was at ZF race camp as scrutineer and here some of my impressions. I didn't have very much time to watch the track, but most of the electric cars there were able to pass all parts of scrutineering and to do at least some test drives.

Zwickau's car is quite impressing with four motors. Unfortunately they had some trouble and never had more than three motors working at the same time. But if they get it fully working until Hockenheim I'm pretty sure they will perform extremely well.

The electric cars from Dresden and Diepholz passed scrutineering and did some testing, but both cars weren't very quick, looked as if this was one of there first drive at all. But already nice work to have it running in rules compliant condition right now.

I somehow missed to have a close look at the Munich car and I'm not sure if they passed scrutineering and if they were able to drive.

Karlsruhe came only with the combustion car and the GreenTeam arrived pretty late because of some trouble with the car. They passed the electric scrutineering but the event was over before they had a chance to drive.

GFR's electric car was also there but not able to run.

Also the performance of the combustion cars was quite impressive. Rennteam and Karlsruhe didn't have any trouble with scrutineering and were able to drive a lot with only minor problems. Munich didn't have problems with scrutineering either but they had some trouble with their engine.
TUG arrived a bit late because of a suspension failure while testing at home. Once more their car is looking amazing. They didn't have much trouble passing scrutineering and were also able to do quite some testing. But on Saturday they suffered once more a suspension failure and the event was over for them.

Lap times were hard to compare as track conditions changed all the time due to rain and sunshine.

[DMuusers]

Originally posted by Thrainer:
Daniel, nice drive. Your motors seem to have a lot of low end torque, so I assume they drop off a lot at higher revs (since the power rating is only about 27 kW)?

How much does she weigh now? Novena is about 104 kg at the moment... without powertrain. She's undergoing another motor upgrade.

Can somebody post results from the ZF Race Camp, especially of the electric cars? I'm curious about Munich's 200 kW car, KA and Greenteam.

Regards,
Thomas

The motors are pretty consistent up to 8000 revs. She weighs in at just below 175kg and so far there aren't major complications. Currently we're just testing range, energy usage and speed. We also did some skidpads and so far the car seems faster than the DUT10.

[Bemo]

I heard some rumors that you killed a set of motors Daniel. Is that true?

[mech5496]

At first when I saw 200kW (Munich e-car) i was damn sure that it was a tupo, but when I doublechecked on their webiste it seems that is not... So what's with that?! What about torque figures? 200kW is at least impressive, really curious about track performance here... Have you compared it with your combustion car?

[DMuusers]

Originally posted by Bemo:
I heard some rumors that you killed a set of motors Daniel. Is that true?

Well I know that water got in one of the motors some months back, but I'm not sure if it was destroyed by it.

[Bemo]

That's why I asked. Storys can change a lot while travelling from the Netherlands to southern Germany. http://fsae.com/groupee_common/emoticons/icon_wink.gif

[JasperC]

The team has had to send some guys out on a road trip to AMK to get some things fixed twice (that I know of). One issue was, as Daniel said, a motor not being waterproof, the other I can't remember what happened (something that was discovered during dyno testing a few months ago).

But I'm not actually part of the team anymore, I'm just one of those lousy alumni who stick their head in from time to time. So I'm probably not the most accurate source when it comes to things like this. http://fsae.com/groupee_common/emoticons/icon_wink.gif

Cheers,

Jasper Coosemans
DUT Racing Team 2008-2010

[Bemo]

Same for me Jasper. But we'll see what the DUT11 is able to do on the track this week at Silverstone!

[Thrainer]

Originally posted by blister:
Jasper,

I am really excited to hear that from your team! We are also in a conceptual stage, altough we have still one race ahead.

Two motors is also our concept. Hopefully your car is not 50kg lighter than ours like in the ICE Age :-)

I'm very surprised the difference between the DUT and AMZ cars at FS2011 was only 2 kg besides 13" wheels and 1.3 kWh more energy on the latter.

We are looking forward to competing at FS Austria, without the power limit of 75 kW and efficiency scoring basically meaning "use everything your batteries offer", next week.

Regards
Thomas

[Lorenzo Pessa]

Car from Pisa launched last week.

Here some pics.
h t t p s :/ / picasaweb.google.com/117302026900273712110/2011ETkenAcademicPresentation

[Diablo_niterider]

But I'm not actually part of the team anymore, I'm just one of those lousy alumni who stick their head in from time to time. So I'm probably not the most accurate source when it comes to things like this. http://fsae.com/groupee_common/emoticons/icon_wink.gif

Cheers,

Jasper Coosemans
DUT Racing Team 2008-2010

+1 http://fsae.com/groupee_common/emoticons/icon_frown.gif wish there was a special category in FS for alumni

[Thrainer]

Originally posted by Diablo_niterider:
wish there was a special category in FS for alumni

It's called "event officials".

[Bemo]

That's something I might consider next year. This year I'm just there as a Rennteam hooligan http://fsae.com/groupee_common/emoticons/icon_wink.gif

[TMichaels]

Originally posted by Thrainer:
<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by Diablo_niterider:
wish there was a special category in FS for alumni

It's called "event officials". </div></BLOCKQUOTE>

+1

[flavorPacket]

Originally posted by TMichaels:
<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by Thrainer:
<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by Diablo_niterider:
wish there was a special category in FS for alumni

It's called "event officials". </div></BLOCKQUOTE>

+1 </div></BLOCKQUOTE>

+2

Also, there is always the University of Phoenix Online...

[wagemd]

Originally posted by flavorPacket:
<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by TMichaels:
<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by Thrainer:
<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by Diablo_niterider:
wish there was a special category in FS for alumni

It's called "event officials". </div></BLOCKQUOTE>

+1 </div></BLOCKQUOTE>

+2

Also, there is always the University of Phoenix Online... </div></BLOCKQUOTE>

Some say they have a great Formula team...