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Aeroshell Nextbreak Issues

Aeroshell Nextbreak Issues

  • Roll cage and canopy intersect by about half an inch

    • can be fixed by tiny changes to roll cage or cutting holes in back of top shell

  • Front wheels

    • cut 2 inches back into the shell

    • have to remove one bulkhead

    • lights may want to move, since its close clearance wise

      • they could move behind the second bulkhead

    • piece of wood in the shell, would intersect

    • shell to shell on the right side has to move

  • Back Wheel

    • Whole back bulkhead section has to go

    • lots of space on either side of the wheel

  • Bulkheads

    • wider in the back so shave back side bulkheads by a few inches

    • also shave front side bulkheads in the front by a few inches

    • shave small bulkhead in the front

    • top shell bulkheads might intersect with frame at the front, need a few inches to shave

  • Frame to Bottom Shell Tabs

    • Front ones intersect

    • first side is good

    • second one is bad

    • third is sooo cooked

    • back ones should be fine

  • Frame sits on front of curve

  • 3D print in back of daybreak has to be removed

  • 000

    • enclosure to the left of the frame at the back will run into bulkhead, if we could shift it a few inches backwards then it would be in the space where the previous back wheels are and we’re good

    • front ballast box would hit all of our bulkheads in the front

  • double check egress and if the dashboard bar fits in the canopy cutout

 

 

 

TLDR:

Back wheel

image-20250917-005716.png
IMG_3664.jpeg

Front wheel

image-20250917-010331.png
IMG_3661.jpeg

Roll Cage

image-20250917-010813.png

 

Aeroshell

  • Lots of bulkheads have to be shaved off slightly (some need to be removed) since the frame is a bit wider

  • Bottom Shell to Frame attachment has to be removed from daybreak

Mechanical

  • Cooling: ducts will probably have to follow the path of daybreak

  • Enclosures

    • some on the side of the frame need to be moved slightly to avoid bulkheads

    • if they are supposed to attach to the top shell, they now need to attach to daybreak topshell

  • Ballast Box: intersects with front bulkheads

  • CG will be changed since topshell is heavy

Electrical

  • Where side lights are on daybreak intersect with the wheels so needs to move

  • relaminate topshell

  • wiring

9/16/2025 Leads

Ballast box will stay location / change shape for front mount for aeroshell curve

Array layout will remain the same with the new cells

 

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