5/14

figure out what is worth fixing 

str

• only the hex couple connecting to the wheel will be changed, welding not an issue 

• i will cad new quick disconnect 

• josh will buy 7075 and 6061

• josh will do hand calcs to figure out by 5 days from now

• should tell ergo that QD is changing 

• gerard: last time he touched str was spring break: lower one alr remade, just upper to be made now

• drill thru u joints yes, just clamp it well on the mill

• kayla finish daybreak redesign by 5/22

• pillow blocks: machine a simple spacer + reduce the height of top block

• cotter pins

suspension

• currently only replacing 1 shock. concern: affects handling, would unbalance?

• can we buy new shock from jenson usa?

• how is pushrod mount being connected to bottom CA? bracketed? welded? but no one here to weld alu. bracketing is prolly quicker but need to do analysis on strength, andrew can do 

• have jacob contact emily if gerard cant help 

• jacob miight come to comp

• waiting for kayla to finish ca design, then sendout waterjet order, then postmachine + do grooving for spherical bearing

• upper ca selected spherical bearing has larger ID than 1/4"?

• motion ratio length is smth kayla 

• only front CAs are changing, not rear ig? confirm with kayla 

• new shock coming when? ask michael 

• CA stock maybe needed to send to lee for waterjet

• current shocks 7.875 eye to eye, 2.25 travel

• shock we ordered can be returned within 30 days of ordering. when did michael order? like 2.5 wks ago.

unsprung

• getting a new motor rotor from china bc brake pad is not making full contact 

• safety wiring: how much do we need to do? for all critical fasteners, which is all dyn fasteners that dont use flex top lock nuts. and all blind holes.

• hand brake: teeth are dull, bar is bent, rubber band replace w spring? josh

• bolt holes in small bolts for safety wiring, should be carbon steel 

• buy washers once new rotor has arrived from china

• need to disassemble calipers and oil the pistons, bc they dont fully retract after powered run 

• banjo bolt- either buy bolt or replace with front left, depending on if parthiv wants the pressure sensor. follow up with parthiv in a few days.

• ic might have safety wire drilling jig that can clamp into vice

to dos:

• cesar send pics + take measurements of new quick disconnect -> i cad it and cad the new upper steering shaft (steel)

• josh will buy 7075 and 6061

• josh will do hand calcs to figure out by 5 days from now

• josh check for new shock arrival

• andrew do analysis on bracketing pushrod mount to bottom CA

• cesar ask jacob to ask emily if she can help weld pushrod mounts (likely last wk of may/first wk of june)

• me ask philip if we need to buy ca stock to send to lee for waterjet

• me and josh will measure bolt hole diameter and machine bolt holes tmr

• josh next time he goes to pickle: 1) take closer look at handbrake issue 2) if this seems like a valid solution, bring hand brake upper bar to etc to grind it sharper

• andrew - few days from now, follow up with parthiv on banjo bolt/pressure sensor needed in front left?

• josh will ask electric if theyre getting keys this wknd. our cohort leads are philip gerard kenta harshit 

POWERED RUN: dynamics nothing changes for powered run except new shock if it comes in 

5/28

currently at pickle, did test fit of lower str shaft.

• redo the spacer (make it like 0.760 then go down by thou and test fit)

• lower shaft OD perfectly fits in bearing, OD = 0.6235" -> keep in mind for upper shaft

• TAKE THE RACK OFF BEFORE U LEAVE

• take all pillow blocks before leaving

from kayla call:

coordinate whether we can make new rod ends 

all bottom rod ends too big 

pick new rods ends ( first check if we have any)

control arm status: how to do it matrix method with non 2 force members

Clevis pin holes on lower shaft need to be 10 degrees offset 

5/29

• assemble wheels down and check how brake disc fits in calipers

• cad control arms & send to jacob, then do truss solver, then do tiny bit of research -> asked kayla

• check CAD for str shaft exact eye to eye dims, shows 7.202? asked gerard

• bolted joint str

• helicoil selection

notes

• new stock should be coming early next week

• info i need rn for truss solver: 

• daybreak weight w driver

• daybreak shock eye distance at: resting, max bump, max droop, 

• truss solver issues: no points for new str rod (IB & OB) OR current str rod (6 #s)

• str wheel thickness: 0.130"

• hole depth: 0.476"

• OD: 0.997 / 1.004" -> make 1"?

• coupler ID: 0.629"

• drill 0.25" thru hole

• decided to wait till later to worry abt the brake interference thing

tmr morning to do

• machine new sleeve- L=1.0", OD= 0.760- (test fit), ID= 9/16"

• machine str wheel QD stopper

• check grooving tool thickness in axle box in garage and tell cesar

5/30

to do today

• put lower str assem on car and check that it works

• ONCE U GET BACK check grooving tool thickness in axle box in garage and tell cesar- its in mill tools box in garage

• send recording link to dyn once it works

• get kaylas measurements - got all the ones we could

notes

dyn meeting notes

• FDR 7/30

• did eplan interview

to do next

• go thru past recordings / notes 

• Read Philips msg and Kayla’s recording 

• check box for shorter QD bolts

• talk to cesar abt manufacturability  his CA design

• get vise measurements on monday for CA design

6/2

str saft dims

1.65-1.71

1.49 + 1.07 + 1.65

bring back tn: both bearings, u joint, rack

 Call w kayla notes

• feedback on the hardware which was the CA blocker 

• bearings small enough to fit in upright but w large enough misalignment

• she wants to downsize rod ends, what are my thoughts so she can do calcs

to dos for meeting:

• settle on CA geometry

• manufacturability: misumi, ask jamie if we can have saturday hours

to do tmr:

• check box for shorter QD bolts 

• grooving tool width

• start making new tie rods and toe rods for current suspension 

• postmachining for pedal box, make spacers, groove for pedal face

• test boring and grooving on rotary table 

6/3

Today: 

• give Philip feedback on his CA design

• Clevis pin: 0.241

• Middle shaft hole (upper): 0.253

• Adavit explain pedal box stuff

Notes

• cesar says str wheel fasteners need to have 2 threads sticking out but i noticed thats not possible bc it prevents the QD from coming off

Tmr:

• make pedal box stuff 

• make tie rods 

• make clevis pin (L=1.64, head thickness=0.0875 non head length=1.553, head OD=0.366, pinhole ID=0.108)

• aero spacers important dims: ID, axial face is flat, and distance between flanges

philip

• kaylas was just a 2d profile

• arch stronger than triangular 

• blind hole better than thru hole

6/5

• cesar/advait comp last yr: shell to frame attachment broke 3 times but we redid the attachments (stronger + more of them) so that shouldnt happen now

• shocks questions to answer in order

1. does pump work?

2. how much pressure drop from removing pump?

3. are we 100% sure all shocks (FL esp) dont leak? test them under multiple conditions to be sure

currently there are no leaks bc recently all rebound settings were put to max positive and all stiffness was put to something (so all shocks on same setting now)

all measurents were made w wheels down

we have to buy a a second shock asap if that one is leaking

4. pressure vs ride height relationship? find thru testing

5. does it work thru its intended range of travel, if not what are the issues?

6. if time it would be nice to characterize these shocks, maybe theres a way to do it by using the current car assembly as the testing setup

tmr: 

• rotary table testing, record w josh

• tap RTH hole for one tie rod

Harshit takeaways from comp last yr

• str extenders bend bc gerard forgot need 2 lock nuts to prevent bending, just need to write everything down even the small things

• most time was spent assembling stuff made right before we left

• pressurize shocks before putting in trailer otherwise no dampening -> stress goes straight to dyn system BAD

• worked well: night shift, day shift ppl, good for doing hella work

• dyn test is last test after everything has passed

• dyn issues: mit tipped, doing it in time figure 8 and circle are fine, slalom is the issue

• tires: bead blaster for tires makes inflation ez

• bring the right tools (9/16 wrench esp)

• try to bring tools that can cut metal easily, angle grinders, level surface (mini table?)

• got new bent tubes for roll cage from some fencing company

• BRING WELDER

6/6

notes

• shocks

• bolted joints

• think thru each operation of ca manufacturing and see if its possible

• consider str angles in CA geometry

Call w kayla notes

talk to cesar abt what he's doing and take str cad from him

brake rubbing: hammer the calipers

kayla: prioritize brakes, CA, pedal box

philip consider str angles?

do tipping calc? for ride height

if bump stop is too high then we reduce travel in design

if need to change RH, lower RH -> changes CA ->

find shock compression & ride height w and wo driver in it

get estimate on shell deflection if we happen to put it on

rn static is 250, get travel till bump stop

at 180 w battery what is rh and travel till bump stop

roll center to cg is kinda high but what is it

kinematic dont matter j need parts on car

6/7

to dos before going to pickle tmr 

• talk to cesar abt what he's doing and get str cad from him 

• get rulers

overall do to dos

• bolted joints

• suspension measurements (think thru)

• CA manufacturing thinkthru all ops: clamping (flat faces needed where), tool interference, are certain features/profiles hard to do (look at cad), WHAT TOOLS we using (maybe practice boring on lathe?)

6/8

notes

• organization: our stuff in garage rn, plus toolbox in hallway

Upper shaft sticks out 1.611” from bearing face (inner)

Look at cesar CA cad and give feedback on manufacturability 

Tmr:

• Machine Gerard spacer L=1.71”

• Boring operation

• Make lower shaft spacer (bring lower shaft) length 1.56 at least 1.75 ideal ID>0.587

• Str arm spacers 4x ID .25 OD length=0.300” steel OD= .35-.400

waterjetting stuff

dxf doesnt transfer units over

we dont know if lee has stock - he does for CAs

• CA maybe

• seatbelt tabs yes

• str wheel no?

• pedal box no bc need 1/4 in

• batt box pins 

tmr: 

• square stock for seatbelt tabs

• boring op

• reduce lower shaft spacer OD 

• cut the stock for battery box pins

• check grooving tool depth (radial)

6/10

today pickle:

• find min stock size to order for waterjetting (pedal box, batt box pins, seatbelt tabs)

6/11

• size helicoils

• ca manufacturing plan

• bolted joint analysis

6/12

tmr:

• cut 4130 plates to 1/4" thicknesses

• rotary table nut wrench sizes: 1/2, 9/16, 11/16, 7/8

6/13

• cesar will weld tmr, needs practice stock, ill bring the spacer from my apt

• tmr: ask ic where their body cabinet is for helicoil kit

6/14

• sizing remaining hardware today

• bolts??

• ended up sizing all hardware, practiced helicoiling a 14-28 rht hole (used drill at pickle)

• worked w cesar to make sure the CA cad works w the ret rings we chose to not have interferences/reduced misalignment

6/15

• figure out pedalbox spacers to machine 

• Spacers needed for pedal box: (all aluminum)

5x .5265 OD .3125 ID,  .5 inches in length

2x .5265 OD .3125 ID,  .25 inches in length

6/16

• check if ic has lh 1/4-28 LH tap in their cabinet in the shop, if not then we go RHT for all helicoils & rod ends

• to machine this week: pedalbox spacers, current susp spacer ID: 0.65 OD: 0.85 thickness: 0.064 

• make inboard tie rod spacers axial length = (0.505-0.375)/2 ID=0.25, OD=0.4”

• lathe concentricity issues so only made pedalbox spacers and 3 tie rod spacers

6/17

machining

• current susp spacer 4x per side, 16x total? ID: 0.625 OD: 0.85 thickness: 0.064 steel

• part 1 more tie rod spacers axial length = 0.065+parting tool width

notes

• stuff left to do from above: grooving, shocks, (pickle) check if old tie rods can be used as new toe rods for current susp, are we good for str wheel bolts (b&b)?, comp prep

UPDATE CA PLAN NUMBERS W MOST UPDATED CAD

6/18

• drill 0.625" hole in rotary table piece, then bore & groove

• me and gerard faced the 6 upper CAs, i did practice bore using rotary table and with boring bar, then did practice groove, then did actual bore and groove on one FU CA

• gonna move daybreak later and get more truck hours w kellen and gerard

6/21

machining to dos

• spacers (link to sheet)

• rack extender 

• rack stopper

• shave down rear shock extender cup

other to do

• check rack extender bolt and test fit to ensure it twists tight. if not then gotta fix clevis

do rn

make cad for spacers

ensure theres cad for rack stopper/extender

figure out what amt to shave down extender by 

dyn meeting notes

• maybe need jam nut between rack and rack extender

• make sure ergo meets regs

• make sure rack extender bolt is properly safety wired

shock stuff

• rebound setting:  max - is most rebound (fastest), max + is slowest

• the CAs that we have ready are RL and FU

• pushrod to pushrod tab bolt needs to be at least 1.5" threaded length

• unthreaded length <= 1.075"

• need to decompress shocks to increase pushrod length, which needs to be done rn bc our ride height at 200psi is still like slightly under 100mm and that's without shell/ballast

• pushrod tab to CA bolt unthreadd length <= 0.625" lock nut length  = 0.3" so bolt length >= 0.925" 

• current walls inner are 0.57" apart, eliinating spacers would make it like 0.3725"

• bolt hex head d=0.5" (wide) 0.435" (narrow)

• Grooved last 2 upper CAs and 5 lower CAs. Chipped grooving too unfortunately

6/22

• Did last grooving operation, drilled and tapped a few upper CAs, drilled and tapped some lower CAs, helicoiled a bunch, learned to break off tang using some pliers and then sanding, test thread the bolt, guided Josh and sohan with doing spacers and pushrods, discussed some steering stuff (extender / bolt) w Josh