The final week of the build is upon us and there is still much to do. However, much progress has been made since my last post. The array has been strengthened with spars and part of the canopy was cut out of it for a driver egress hatch. Megan and Courtney laid out the cell design for the top of the array and hopefully the solar cells will be installed in the next day or so.
The lower body received its first few pieces of the suspension as we attached some mounting brackets to the inside of the car. The spars inside the car were also notched for the array, which was mated to the lower body this past weekend.
The trailer for the solar vehicles was given an overhaul this past week as we tore out the old ramp and installed a new one. This new system will be able to accommodate our new car as well as the 2005 Sunseeker.
Bronco Pride,
Joshua
June 2, 2010
May 26, 2010
Endless Nights
The days are beginning to blend together as the team moves forward towards our June 8th deadline. Last Friday was a good break from the mundane as we hosted tours of 3rd grade students from the Portage area. Nick got the star treatment of the day because the kids all wanted the driver's signature after he took the car for a spin. Later that day, the team managed to free the array from its mold, with no damage to either part!
The spars were glued into the body and a lightweight filler was placed around the edges of the material to provide a radius for the fiberglass strips that will reinforce the spars. Several team members have also been assisting Dr. Bazuin and Dr. Kapenga in preparing the car for its electrical components.
AJ, Nick, and myself, with some assistance from others, have begun machining some of the steel parts for the car, such as suspension mounts and the roll cage. Many of our aluminum components are being machined by Glenn Hall, John Cernius, and John Hurry, the owner of a local machining business.
Bronco Pride,
Joshua
The spars were glued into the body and a lightweight filler was placed around the edges of the material to provide a radius for the fiberglass strips that will reinforce the spars. Several team members have also been assisting Dr. Bazuin and Dr. Kapenga in preparing the car for its electrical components.
AJ, Nick, and myself, with some assistance from others, have begun machining some of the steel parts for the car, such as suspension mounts and the roll cage. Many of our aluminum components are being machined by Glenn Hall, John Cernius, and John Hurry, the owner of a local machining business.
Bronco Pride,
Joshua
May 19, 2010
The Final Lay-up
The weekend saw another step forward in the progress of the build. The array mold was removed from the plug, some minor damage was repaired, and then the surface was polished. Starting Monday, we laid the material for the array into the mold and vacuum bagged it to remove excess resin. Earlier today the bag was removed from the final layer and we are all very happy about the quality of the part. The plan for tomorrow is to remove the array part from the mold.
The spars are nearing the point of installation. Megan and Kenwood sanded the surfaces of the spars in preparation for bonding them together with strips of fiberglass. The fiberglass bonding will be performed in a few days, at which point the spars will also be permanently installed into the body.
Earlier today, Megan and Courtney had some training sessions in the 2005 car. Neither of them were very familiar with the car so they only did laps in a parking lot and around the WMU Business Technology Research Park.
Bronco Pride,
Joshua
The spars are nearing the point of installation. Megan and Kenwood sanded the surfaces of the spars in preparation for bonding them together with strips of fiberglass. The fiberglass bonding will be performed in a few days, at which point the spars will also be permanently installed into the body.
Earlier today, Megan and Courtney had some training sessions in the 2005 car. Neither of them were very familiar with the car so they only did laps in a parking lot and around the WMU Business Technology Research Park.
Bronco Pride,
Joshua
May 14, 2010
Busy Times
Sorry about the delay in this post. We have been so busy with the car that I haven't had the time or energy to write a new entry. But that should also speak for how much progress the team has made in the past week.
The primary projects for the past week have been the array mold and the lower body spars. The array plug received its final coating of primer Friday. Over the weekend several team members spent countless hours sanding the plug to a nice, smooth surface. Then the plug was polished and coated in mold release compounds. Starting early this week, the mold was constructed one layer of fiberglass at a time. The plywood braces were attached and reinforced. We hope to remove the plug later tonight.
The lower body has been receiving its fair share of attention as well. Sheets of Plascore board have been cut following templates printed from a CAD program (a great example of cooperation between our build and design teams.) Over the past few day we have been working on trimming the pieces for a precision fit.
A few other tasks have been completed this week. Megan began sorting through the tool boxes and Tim checked the tires for age cracks. Much of the metal that will be required to build the suspension and roll cage were purchased, and the team went to seen a screening of the film "Cherry", which was partially shot here at Parkview in 2008.
These past few weeks would not be possible without the support of all the staff here at Parkview. The Dean's Office has backed the team's efforts 100%, the staff in the IME and Advising offices have provided several home-cooked meals for the team. Fred Sitkins has serviced the team in many ways, from securing vehicles for us to use on the race, to gaining donations of food and drinks. Glenn Hall and John Cernius have and continue to assist the team in the fabrication of the suspension and internal frame of the vehicle. To all these people, and those not mentioned, the team extends our heartfelt gratitude. Without your support, this project could not become a reality!
Bronco Pride,
Joshua
The primary projects for the past week have been the array mold and the lower body spars. The array plug received its final coating of primer Friday. Over the weekend several team members spent countless hours sanding the plug to a nice, smooth surface. Then the plug was polished and coated in mold release compounds. Starting early this week, the mold was constructed one layer of fiberglass at a time. The plywood braces were attached and reinforced. We hope to remove the plug later tonight.
The lower body has been receiving its fair share of attention as well. Sheets of Plascore board have been cut following templates printed from a CAD program (a great example of cooperation between our build and design teams.) Over the past few day we have been working on trimming the pieces for a precision fit.
A few other tasks have been completed this week. Megan began sorting through the tool boxes and Tim checked the tires for age cracks. Much of the metal that will be required to build the suspension and roll cage were purchased, and the team went to seen a screening of the film "Cherry", which was partially shot here at Parkview in 2008.
These past few weeks would not be possible without the support of all the staff here at Parkview. The Dean's Office has backed the team's efforts 100%, the staff in the IME and Advising offices have provided several home-cooked meals for the team. Fred Sitkins has serviced the team in many ways, from securing vehicles for us to use on the race, to gaining donations of food and drinks. Glenn Hall and John Cernius have and continue to assist the team in the fabrication of the suspension and internal frame of the vehicle. To all these people, and those not mentioned, the team extends our heartfelt gratitude. Without your support, this project could not become a reality!
Bronco Pride,
Joshua
May 5, 2010
The Final Push Begins
Finals are over and the college has become eerily quiet with only one exception. The Plastics lab here at the Parkview campus is full of activity. Through the entire month of May, the WMU Sunseeker team will be putting in long hours to see the project through to completion for the rayce, which begins on June 12th. Over the past week the progress has been remarkable.
The lower body was finally released from the mold on Saturday. Although there was some damage to the exterior surface, it still exceeds our expectations. Most of the damage was repaired yesterday and today and the plan is to have it moving on to the next step in the process by early next week.
The foam plug for the array was also worked on this past week. A layer of spackle was placed onto the foam to give a smooth surface. Once that was completed, we applied a protective layer of PVA. Yesterday, Doc sprayed the first layer of primer onto the plug. Today's task has been to fill and sand the imperfections in the surface so the application of primer can continue Friday.
Tonight, we also had a team meeting to discuss where we are on the project. There is lots of work to do and many components of the car to assemble, but things are looking up. Be sure to follow along as we breathe life into the many ideas and designs, turning this car into a reality.
Bronco Pride,
Joshua
The lower body was finally released from the mold on Saturday. Although there was some damage to the exterior surface, it still exceeds our expectations. Most of the damage was repaired yesterday and today and the plan is to have it moving on to the next step in the process by early next week.
The foam plug for the array was also worked on this past week. A layer of spackle was placed onto the foam to give a smooth surface. Once that was completed, we applied a protective layer of PVA. Yesterday, Doc sprayed the first layer of primer onto the plug. Today's task has been to fill and sand the imperfections in the surface so the application of primer can continue Friday.
Tonight, we also had a team meeting to discuss where we are on the project. There is lots of work to do and many components of the car to assemble, but things are looking up. Be sure to follow along as we breathe life into the many ideas and designs, turning this car into a reality.
Bronco Pride,
Joshua
April 28, 2010
Releasing the body
During the past few days the team has been working on removing the body from the mold. we have hit quite a few snags along the way, including areas where the mold won't release from the body. As of tonight, approximately 60% of the body surface shows signs of release. In some of the areas that refuse to release from the mold, we have begun to cut away the mold itself in an attempt to encourage separation. Unfortunately, this has caused some slight damage to the surface of the body, but its nothing we can't repair.
On a lighter note, this Saturday the team traveled to the Celery Flats historical Area in Portage for their Green-A-Thon event. We set up in a central location at the event and attracted lots of attention. The public's interest in the team and the vehicle was astounding. It was a successful day. A great thanks to the City of Portage and all the volunteers and organization that made the event possible.
Bronco Pride,
Joshua
On a lighter note, this Saturday the team traveled to the Celery Flats historical Area in Portage for their Green-A-Thon event. We set up in a central location at the event and attracted lots of attention. The public's interest in the team and the vehicle was astounding. It was a successful day. A great thanks to the City of Portage and all the volunteers and organization that made the event possible.
Bronco Pride,
Joshua
April 22, 2010
Building the Body
A huge step forward was taken this past weekend. The first layers of fabric for the lower body of the 2010 Sunseeker were laid into the mold. It all began with a layer of surface coat, which will give the outside of the car an unbelievably smooth surface. Then more surface coat was laid into the mold, followed by 2 layers of fiberglass, some patches of carbon fiber for re-enforcement, and just enough resin in between all of that to bond everything together. Once it was all laid into the mold, we placed a vacuum bag over the mold in order to pull the fabric tight to the sides of the mold while removing any excess resin. The lay-up was left over the weekend to cure.
On Monday, Abe, Nick, and Scott from SC Enterprises came into the lab to remove the vacuum bag system and check on the first layer. To all of our relief, the lay-up was a success, aside from a few small blemishes that were removed during the Wednesday work shift.
On Wednesday, the team placed 2 more layers of material into the body, Nomex honeycomb reinforcement and another layer of fiberglass. These layers were once again bagged and placed under a vacuum. The team would like to extend many thanks to Scott and all the staff at SC Enterprises for their commitment to helping us realize our goal.
One thing that we forgot to mention in last week's post was another driver training session. On Friday the 9th, Mitch took another ride in the 2005 Sunseeker. We drove down to Vicksburg and back, attracting lots of attention along the way!
Bronco Pride,
Joshua
On Monday, Abe, Nick, and Scott from SC Enterprises came into the lab to remove the vacuum bag system and check on the first layer. To all of our relief, the lay-up was a success, aside from a few small blemishes that were removed during the Wednesday work shift.
On Wednesday, the team placed 2 more layers of material into the body, Nomex honeycomb reinforcement and another layer of fiberglass. These layers were once again bagged and placed under a vacuum. The team would like to extend many thanks to Scott and all the staff at SC Enterprises for their commitment to helping us realize our goal.
One thing that we forgot to mention in last week's post was another driver training session. On Friday the 9th, Mitch took another ride in the 2005 Sunseeker. We drove down to Vicksburg and back, attracting lots of attention along the way!
Bronco Pride,
Joshua
April 14, 2010
Progession to the goal
Greetings and Salutations fellow Sunseeker enthusiast,
Today was an extremely productive day. Mitch, Byron and myself have finished buffing the mold. Nick and Josh worked on patching up a few blemishes on the inside of the mold. Tonight's progress on the new 2010 Sunseeker has been astonishing. Abe helped us get a full list ready of things that still need to be done before the rayce. The crew has also lifted the 2005 solar car array off the car and onto the stand. Byron re-enforced some troubled areas on array. We are finishing up some repairs on the 2005 car to get it back in condition for driver training.
Bronco Pride,
Megan
Today was an extremely productive day. Mitch, Byron and myself have finished buffing the mold. Nick and Josh worked on patching up a few blemishes on the inside of the mold. Tonight's progress on the new 2010 Sunseeker has been astonishing. Abe helped us get a full list ready of things that still need to be done before the rayce. The crew has also lifted the 2005 solar car array off the car and onto the stand. Byron re-enforced some troubled areas on array. We are finishing up some repairs on the 2005 car to get it back in condition for driver training.
Bronco Pride,
Megan
April 7, 2010
Preparing the Mold
Thursday saw the beginning of a great commitment for several team members. Mitch and Nick, the primary drivers for the 2010 Sunseeker, began their driver's training. It was Mitch's turn on the road as he took the 2005 Sunseeker for a short drive south of town. Several other team members also partook in this as crew members in the chase and lead vehicles.
Tonight the team began to prepare the mold for building the body. We scraped out pieces of tape, sanded down rough sports and then applied surface coat to the mold to fill in any damaged areas. We planing on beginning to lay the fiberglass and carbon fiber within a week, so the car will soon come to life.
Bronco Pride,
Joshua
Tonight the team began to prepare the mold for building the body. We scraped out pieces of tape, sanded down rough sports and then applied surface coat to the mold to fill in any damaged areas. We planing on beginning to lay the fiberglass and carbon fiber within a week, so the car will soon come to life.
Bronco Pride,
Joshua
March 31, 2010
Mold completed
The past few days have been very inspiring for the team. On Friday night, AJ, Mitch, Joel, Nathan, Byron, and myself worked on completing the mold. The plywood supports were attached to the mold. We then proceeded to add the final layer of fiberglass to the mold. The work continued until 4am and a heartfelt thanks goes out to those who stayed to help.
Tonight the team made another great advance. The mold was taken down from the table, and inverted. We then began attempting to separate the edge of the mold from the foam. Once the edge was loosened, we attached air lines to the plug and it separated from the mold. The mold needs a little work, but it definitely exceeds our expectations. I finished the night by trimming the outside edge of the mold to give us a good edge to seal to when we begin building the body next week.
Bronco Pride,
Joshua
Tonight the team made another great advance. The mold was taken down from the table, and inverted. We then began attempting to separate the edge of the mold from the foam. Once the edge was loosened, we attached air lines to the plug and it separated from the mold. The mold needs a little work, but it definitely exceeds our expectations. I finished the night by trimming the outside edge of the mold to give us a good edge to seal to when we begin building the body next week.
Bronco Pride,
Joshua
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