openCortex: Composite Monocoque Construction page




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DISCUSSION TOPICS	Composite Monocoque Construction OCID nd00000055	SIBLING CATEGORIES Composite Monocoque Design

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	Related Content (15)

	B2B Chassis_11 Photo by eloy avila created 5/7/2003 submitted 5/7/2003 07:24:39 PM Here the Back2Back Burner chassis and ribs on the lower shell. This view allows a better sense of how all the pieces fit together.

	B2B Chassis_6 Photo by eloy avila created 5/7/2003 submitted 5/7/2003 07:18:24 PM Here the Back2Back Burner chassis front end is bonded with Hysol adhesive. The chassis was held together while the adhesive was applied and bagged. The chassis was then cured under vacuum and in an oven.

	Reinforcing a delaminating carbon fiber-honeycomb panel Photo by Alex Selkirk created 6/6/2001 submitted 3/15/2002 07:38:53 AM In order to slow down the delamination process and reinforce the monocoque chassis, the Backburner team added this aluminum plate by drilling holes through the panel and fastening it on the other side. The panel had started to delaminate after the many thousands of miles it had raced as the main mounting point for the left front suspension when the car was called the Afterburner. The car ran without incident through American Solar Challenge 2001.

	B2B Chassis_7 Photo by eloy avila created 5/7/2003 submitted 5/7/2003 07:20:09 PM Here the Back2Back Burner chassis is unmasked after the lengthwise bonds are cured. The panel had a peel ply layer that was left on for protection while it was worked on.

	B2B Chassis_4 Photo by eloy avila created 5/7/2003 submitted 5/7/2003 07:17:04 PM Here the Back2Back Burner chassis end is bonded with Hysol adhesive. The seams were first prepped by sanding with a fine grit paper and then cleaning with MEK and masked. The chassis was done in several cycles to allow bagging and vacuum. The ends were done separetely and the lenghtwise seams were done togehter.

	B2B Chassis_8 Photo by eloy avila created 5/7/2003 submitted 5/7/2003 07:22:09 PM Here the Back2Back Burner chassis in the oven cooking under vacuum. Eerik, cut-and-fold expert, works on making it perfect...

	B2B Chassis_10 Photo by eloy avila created 5/7/2003 submitted 5/7/2003 07:23:44 PM Here the Back2Back Burner chassis all done! You can see Eerik wants to drive it around already. Notice the bonds were sometimes on both sides of a seam as in the front and rear ends.

	Panel Tub Chassis Photo by eloy avila created 9/26/2002 submitted 11/17/2002 06:11:01 AM The Stanford team pioneered using a carbon sandwich panel used in a cut and fold method of chassis construction. Here you can see the panel before it is transformed into the tub/chassis.

	Panel Tub Chassis Photo by eloy avila created 9/26/2002 submitted 11/17/2002 06:10:56 AM The Stanford team pioneered using a caron sandwich panel used in a cut and fold method of chassis construction. Here you can see the panel before it is transformed into the tub/chassis.

	sample wet layup Photo by eloy avila created 6/26/2002 submitted 7/6/2002 09:16:11 PM Sample composite panels are layed up for testing. Here PVA mold release is applied to a non-porous surface before the wet layup to allow release of the panel after cure.

	test composite panel-top Photo by eloy avila created 6/26/2002 submitted 7/6/2002 09:28:43 PM Here a top layer of carbon fiber is placed on the nomex core. The top fabric was previously wetted with epoxy.

	B2B Chassis_1 Photo by eloy avila created 5/7/2003 submitted 5/7/2003 07:11:50 PM Here the Back2Back Burner chassis panel is ready to be folded into a box-like chassis. The panel was carefully routed to allow the bends to be of exact radius.

	B2B Chassis_2 Photo by eloy avila created 5/7/2003 submitted 5/7/2003 07:13:56 PM Here the Back2Back Burner chassis panel is folded into a box-like chassis. The seams were cleaned with MEK and masked. Pre-made carbon L-brackets were used to bond the seams.

	B2B Chassis_3 Photo by eloy avila created 5/7/2003 submitted 5/7/2003 07:15:42 PM Here the Back2Back Burner chassis is bonded with Hysol adhesive. The seams were first prepped by sanding with a fine grit paper and then cleaning with MEK and masked.

	Making L-Brackets Article by Alex Tung created 1/21/1999 submitted 3/8/2002 10:49:56 PM These are notes on how to wet-layup carbon L-brackets which were used to hold the Stanford car together in 99 and 01.