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Bottom Shell to Frame Attachment Plan (WIP)

Bottom Shell to Frame Attachment Plan (WIP)

For reference, here is a picture of the bottom shell to frame assembly.

image-20260412-034231.png

A few changes we will be doing is we will be changing this so the M5 Screw faces downwards instead of upwards. I am making this change because it’ll be impossible to remove the screw in this state. I also believe the rubber is removable. I will be removing the rubber so the clamp can bond better to the 3d print. Another thing I noticed in my visit to pickle today is the wire harnessing. We were able to rotate the wire harnessing so that should not be a problem when mounting this. What I could see being a problem is the brake lines since that is not rotatable. It’ll make mounting the holes much harder. I will be going up to pickle again early this week to come up with a plan on the brake lines.

 

My current plan to mount BSTF:

  1. Put frame with dyn on shell. We will then get a wooden platform and align the bottom shell so it is good with the frame. I do not know whether we should also have canopy and top shell for this. It may be overkill and the parts won’t be ready when we are mounting this so we will have to suffice with just this. If there is misalignment, the top shell will then be shifted slightly.

  2. We will draw squares with a grey sharpie on areas which we will mount the BSTF assembly. We can slide the wooden platform off so we can structural adhesive the 3d prints to the shell face. For areas with slight curvature, we will need to trim the platform so it is completely in contact with the flat portion.

  3. We let the structural adhesive cure. Now, the 3d print assembly with one half of the pipe clamp are on the bottom shell.

  4. We put on the wooden platform again and install the screws. We will be putting the screws facing downards and then we can either use a nylock nut or double hex nut (cesar suggestion) to tighten the nut that are facing towards the bottom shell.

  5. We will use a wrench to tighten the nuts. An area of concern right now is the front bstf assemblies. Willie is allowing me to cut some of the bellypan to fit these in however how would we tighten the nut underneath for the inner screw?

    1. Ideas: Captured nut in the 3d print platform, heat set insert