A Breath of Fresh AIr

The spraying and sanding process on the plug is nearing completion. On Friday, Byron and Doc began the applying the final coat of primer to the plug. Several other team members were also present to assist the process. The next day, the team returned to begin sanding the surface in order to eliminate any imperfections. This began with the application of a light coating of spray paint. As the team sands the surface, the paint will be sanded of the high points while remaining in any pits or rough areas. This technique gave the team a bit of motivation as well. It was very easy to follow the progress of the sanding by simply looking at the color of the plug. On Wednesday night, the sanding was completed.

In addition to the completion of the sanding, several other important tasks were completed. Abe took several team members down to the Projects Lab to begin moving many of our materials out of storage. Several rolls of fiberglass and other materials were brought back to the Plastics lab with the hopes that lay-ups can begin early next week. We were also visited by Scott who gave us lots of advice about the work we we're about to begin. He will also be supplying us with some of the chemicals we will need when we begin the mold. The electrical team continued work on the battery modules. We are hopeful that the batteries from the 2008 car are still in good enough condition to use for the 2010 car.

Today our great friends at Entergy paid a visit to the College of Engineering and Applied Sciences here at Western Michigan University. We look forward to working with them again in the future!


Bronco Pride,
Joshua

Planning Ahead

The past week has seen the usual sanding on the plug. The job has been long and hard, but it is almost done! Many thanks to the team members who were able to contribute to the task.

At tonight's meeting, Abe and Nick shifted the teams attention to the months ahead. The fact that we are behind schedule was made clear, but there is still plenty of hope for the team. Spring Break will be the team's chance to catch back up and ensure our entry into the 2010 ASC. We also began the process of choosing drivers. Height and shoulder width measurements were taken to the final adjustments to the roll cage design could be made. Brian and Gary spent more time working on the design for the rear suspension arm.

The electrical team began testing the battery cells from the 2008 car. The cells were determined to be in acceptable condition and the process of assembling them into modules will soon begin. Meanwhile, more sanding was done to the plug. Once the sanding was finished on a section of the plug, Tim gave a quick demonstration on how to apply Bondo to the surface to fill in any pinholes and gouges. To finish the night off, the lab was given a thorough cleaning.

Bronco Pride,
Joshua

A Dirty Job

The past week has been filled with dust! The team has logged countless hours sanding the plug by hand. It is a long, tedious process, but in the end it should all pay off. The better a job we do now, the smoother the body piece will be (and that means better aerodynamics!) At the Wednesday night meeting, the team finished cutting the plywood supports for the female mold, continued sanding the plug, and began setting up the spray booth.

The work continued today when Nick came into the shop early in this morning and attempted to finish off the sanding. He was eventually joined by Tim, Megan, Doc, and myself. Once the sanding was done, we began to apply icing, a compound that will fill any imperfections in the surface. Now that the icing is on the plug, we can sand it down lightly and then prepare to apply another coating of primer.

Bronco Pride,
Joshua

Prime Condition

Over the past week a major step has been taken in the production of the body for the 2010 Sunseeker. The foam plug had its first coats of primer applied to it. On Thursday, Dr. Engelmann and several team members began the morning by spraying layer after layer of the primer paint onto the sealed plug. On Friday, we had the chance to see how those first few coats turned out. After some inspection and testing with more primer applied by hand, we determined the course of action for the next few days. Byron, Tim, and myself finished the day by hand sanding the entire surface of the plug.

The work resumed today at the regular meeting. Tim took charge of the task of spreading spackling compound over the primer in order to seal the tiny pits on the surface due to the very nature of the polystyrene plug. Once the compound was used to fill the holes, the team went back through and did touch-up work so that the plug will be ready for tomorrow. The rest of the team worked on various projects around the lab. Some began to prepare the spray tent for tomorrow, while others began building sawhorses. Nathan, Megan, and myself began working on sheets of plywood for braces that will support the negative mold once it is completed.

Bronco Pride,
Joshua

The Little Things

The past week has been filled with all of the little tasks that need to be accomplished in order for the work on the plug to be completed. Saturday, Nick, Tim, and myself worked on installing lighting and paper flooring for the spray tent. We also hosted tours for prospective Broncos. Several more layers of the release agent we placed on the plug, including what we hope to be the final layer, which was added tonight.

The meeting got off to a slow start, but soon the team found direction. Nick and Dr. Kapenga gave the entire team updates about progress and goals on both the mechanical and electrical sides of the project. Once the Sparky's (Nick's name for the electrical team) headed up to their lab, the rest of us set to work on preparing the lab for the work to come in the next few weeks. The spray tent's wiring was worked on, the plug was test fitted into it, and the floor and walls were re-papered. Extra pieces of plastic were cut and installed to finish sealing gaps in the roof panels.

Meanwhile, Tim and a few other members made a run to the hardware to purchase plywood sheets for the table. After they cut them to size and installed them, the entire team helped as the plug was carefully placed onto it. Another side project that fell into Megan's hands was the task of creating a small collage of photos on the lab door. It turned out great, and we hope it helps create a little buzz on campus, as we rapidly approach our deadline for completion.


Bronco Pride,
Joshua

Visible Progress

The past week has shown signs of progress for the team. The make-shift ventilation shaft for the sanding tent had filters installed, making the tent safe for its intended use. The holes in the plug were completed and the PVC pipes were installed for the mold release system. Nick, Mitch and myself spent time Monday giving the mold a delicate sanding to remove any imperfections and prepare it for the first coating of release film, which Nick then applied on Tuesday night.

Tonight saw much of the same. Before the work began, Abe took pictures of each team member so we can make a visual roster of the team. Mitch, Megan, and Tim worked on attaching casters to the table so the plug can simply be rolled around the shop. Nick and Byron placed another coat of the release film on the plug. They also got a visit from an expert on the fabrication process. I began making measurements for the plastic screen that will seal off the spray booth, which will hopefully be ready for use by next week. Byron, among other tasks around the lab, started thinking about building the manifold that will feed the PVC exhaust system.

Last Saturday, WMU hosted informational tours for grade school kids. I set up a booth in the Bernhard Center and spoke to the kids about the Sunseeker project. Their interest in the car was absolutely astounding! It was very fun to interact with these kids and explain the basics behind the team and the car. And a quick thanks to Scot Conant for helping me get the display ready for the kids.

Bronco Pride,
Joshua

Spring semseter begins

Work in the lab has resumed. Nick and Tim began the work last Friday and Saturday by working on assembling parts of the spray booth. On Sunday and Monday, several more of us came out to help test fit the pieces and begin making adjustments to them.

Today was the first official meeting of the semester. Nick began the night by laying out the time line for this semester. We now have tentative deadlines by which we should have different aspects of the build completed, including having a fully functional vehicle. Once the formalities were taken care of, the electrical team moved to the electronics lab to continue their many projects, while the rest of us prepared for another shift of manual labor.

Tim briefed us on the work for the night. 3 different tasks were in need of being accomplished and soon everyone was at work. Abe, assisted by Tim, Nick, and Alex began drilling holes in the plug for a ventilation system. Mitch, Megan, and Mike began tearing the old table apart so that they can build 2 smaller, portable tables for moving the plug around the shop. I worked on the spray booth and it is now ready to be installed.


Bronco Pride,
Joshua

And on the third day...

Monday was a quiet day in the lab. I was the only person that was able to make it in, but progress was still made. Before coming to the lab, I searched around town for a store that carried a spackling compound recommended to us by Dr. Engelmann. After I found it, I returned to the lab and applied it to the boards for our spray booth. The boards also received a final coating of paint. While the paint dried, I began hand sanding the entire outside edge of the plug so that the chamfer meets cleanly with the edge of the sculpted part of the plug.

Happy Holidays from all of us here at Sunseeker!

Bronco Pride,
Joshua

Work Day Deux

Josh and I worked on finishing up a few of the projects and making small changes to them. Josh fitted the last roof section and I put some primer on the 1x8 boards. We did some more cleaning for Doc's younger son's birthday party. I think he was having a good time because when we left they were laughing and yelling in the lab. More planning was done for this week.

Bronco Pride,
Nick

First Work Day of the Break

Josh, Hau, Byron and myself made a lot of progress in the lab today. Josh and Hau figured out the last critical measurements for the booth and assembly frame. At the same time Bryon and I added the chamfer to the edge of the plug. I started with a rough cut to get most of the material away. Byron came after and sanded it smooth. We manged to get all of the roof sections done except for one. Of course that is the one that will be the hardest to set in place. Byron sanded the boards and prept them for tomorrow's initial coating of paint and filler.

Bronco Pride,
Nick