Chassis Jigs

[James Morris]

Hows everyones 08 Chassis jigs and chassis coming along? We've just about finished our jig.


James Morris
Swansea Institute of H.E.

[James Morris]

Hows everyones 08 Chassis jigs and chassis coming along? We've just about finished our jig.


James Morris
Swansea Institute of H.E.

[Russ_McLaughlin]

I know VT has theres out to be powder coated, but our team hasn't even started design. Quite the wide spectrum. http://fsae.com/groupee_common/emoticons/icon_smile.gif

[BenB]

Powdercoated chassis JIG???...Fancy!

[Wesley]

We've choreographed the first two parts, but we're at a loss for the finale. Some of the team members are having problems learning the steps.

Oh. That kind of jig...

[js10coastr]

http://www.homestarrunner.com/sbemail44.html

I couldn't resist, it's my favorite episode.

[Russ_McLaughlin]

Chassis not jig... http://fsae.com/groupee_common/emoticons/icon_wink.gif

[pucksaver]

Hey, we are a first year team and are about to begin the chassis. How do you all go about creating a jig? Anyone have any good links/books that go into this topic?

[Christopher Catto]

not books that i know but there may be some that have a section on it.

there are some photos of a nice welding table and jigs in the Helsinki website. dunno the section but pretty much each year they have some photos of the chassis manufacturing.

i would say important are

1) decently sized welding table (2,5x1,2m minimum) with equally spaced tapped holes (say M10x1,5 or M12x1,75). spacing at 50mm is an example. our table at UH was aluminium resting on some decent wood and steel frame

2) various materials (wood, aluminium, steel). i know some would not touch wood for a jig but in fact a thick marine ply plank is very good if you drill holes the diameter of your tubing. for example you can mount planks to hold the horizontal tubing in your chassis. of course, you can make other jigs from steel and mount them off your table

3) various quick release fixtures. these can look like a lever with a sort of a cam mechanism so that when you push it it locks in place. these are good so that you do not have endless bolts to undo. i am not sure where these can be bought though... sorry

4) Plenty of new or old bolts of different sizes and lengths. I know this sounds stupid but some universities barely have budget for the competition. having lots of decent bolts is a nice thought. try to avoid starting your FSAE project by cutting bolts to length!!

5) some pictures of what jigs companies use. I have some pics of how Saleen make their car. you should be able to find these on a google image search. sure, they make a bigger car but the concept is the same. just depends how much money and time you have. seeing the S7 is not expensive for what it is, I think those photos will help you, along with photos from other unis who have spaceframes. print these photos on A4 and stick em on your wall.

6) powerful and sharpened tools: bandsaw, plasma cutter, large pillar drill, lathe, small mill if necessary. this will allow you to make some inserts, plates with elongated holes (useful for some fine tuning), legs to hold things which are high up (main rollhoop for example).

Last thing. Your jigs effort should be appropriate to your effort on the car. No point spending lots of times on jigs if then you have no time for using the 5K data logger somebody sponsored you with.

Here is the first half decent pic I found doing a search for sae chassis jig

http://www.aeromech.usyd.edu.au/sae/images/frame_0706.JPG

[C.Zinke]

Here are some pics of our Jig used for the LR07. If you have the possibility to do lasercuting this is a easy way to build up a jig:

http://www.lionsracing.de/component/option,com_ponygall...ry/catid,52/lang,de/ (http://www.lionsracing.de/component/option,com_ponygallery/Itemid,68/func,viewcategory/catid,52/lang,de/)

[BStoney]

Fred: Please post a picture of the fixturing used at UC...

Thanks
B.J.

[Christopher Catto]

nice idea for the jig with lasercut plates. never seen it before. just a bit worried about little clamping force but for fsae chassis i guess it is ok. i am used to jigs for full size sportscars and 48mm+ dia tubing (rollcages etc too)

again. really like it. laser cutting rocks. at UH we had our brake discs made like that and our teacher made all sorts of stuff for himself like cd racks! i even saw a building in Paris that has laser cut plates of different shapes and sizes covering the whole glassed area making a really cool effect.

[RawePower]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by BStoney:
Fred: Please post a picture of the fixturing used at UC...

Thanks
B.J. </div></BLOCKQUOTE>

I'm not Fred, but I have all the '07 pics. Here's one featuring the master welder.
http://img.photobucket.com/albums/v57/rawepower/IMGP0426.jpg
http://img.photobucket.com/albums/v57/rawepower/IMGP0392.jpg

[paul dae]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">http://www.lionsracing.de/component/option,com_ponygall...ry/catid,52/lang,de/ </div></BLOCKQUOTE>
how did u weld the laser cut plate onto the horizontal plate accurately? i mean some kind of gap could be b\w the two

[BP]

This is the JIG we used to fab our frame last year, it was very simple and made for a great center line reference.

http://img260.imageshack.us/img260/2664/1001692bx1.jpg

[Wes Burk]

We have a SImilar Laser Cut Jig setup to the lions racing team, except that we do not have a nice jig table with coordinate holes so we are having a large sheet like that cut for us also.
Just finished our final chassis structure a few days ago and it should be done in several weeks. We are working with a company in Ontario that CNC cuts and bends tubes with a supplied CAD model. I sent them a proposal, they called me back the next day with a reasonable price quote and said that they could have it done and ready to pick up in two weeks. We were prett happy about that...=)

[flo]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">al plate accurately? i mean some kind of gap could be b\w the two </div></BLOCKQUOTE>

I have found a picture on our website.
http://www.lionsracing.de/comp...ry/catid,96/lang,de/ (http://www.lionsracing.de/component/option,com_ponygallery/Itemid,68/func,viewcategory/catid,96/lang,de/)

The Jig is welded on the surface which will be in contact with the table. The gap between both parts is minimal, so you do not need any filler material.