Flyboy
December 30, 2023, 3:19am
2
Finished Build Pics
I jumped around between different areas of the build a lot, so reading this thread in chronological order might be suboptimal. For the sake of readability, each sub-assembly has its own recap section:
PART ONE: I Vacuum Bagged The Whole Damn Thing 'Cuz I’m Chassis That Way
Carbon forgings are coming along slowly and steadily.
Here’s one fresh out of the mold, still with its dusting of 13 original herbs and spices:
[20230808_231646]
And after much cleanup and grinding:
[20230827_183825]
These flat panels are made by drawing patterns onto craft paper and vacuum bagging them onto end grain balsa, to make a lightweight sandwich that’s carvable with a knife:
[20230812_074904]
All the p…
Part 2: The “JB” in “JB Weld” Stands For "Joining Batteries"
Step 1: Acquire unreasonable amount of P42A
[20221010_202000]
Step 2: Acquire unreasonable amount of JB Weld (not sponsored (but it should be))
[20230507_134147]
Can’t have enough fishpaper
[20240211_115636]
Or P-groups. Or welds.
[20240312_205828]
All the series connections are done with 10AWG flat braid, but I wanted to keep the connections at each end of the pack the same height as the rest, since this chassis is gonna…
Part 3: Unsolicited Deck Pics
The deck starts as a balsa core for the center, plywood core for the rear drop section, and paper core for the flanges
[20240303_203413]
A printed tube is embedded along the underside to carry the torsion rod
[20240303_203509]
The fabric is vac bagged onto it in situ, so the flanges mesh perfectly onto the frame
[20240309_183413]
[20240309_212516]
The torsion rod is a sheet of +/- 45 degree carbon fiber rolled around an 8mm fiberglass tube, up to a diamet…
Part 4: It’ll Cure What Tails Ya
The tail frame starts off as wood core panels like the rest of the project
[20240303_203820]
They all get an initial layer of flax
[20240317_220517]
A bunch of laser cut parts are assembled into a set of chain tensioner mechanisms, which use captive screws to slide the rear axle back and forth
[20240612_223403]
The tensioners are secured to the swingarm panels, and bolted to the wheel to ensure correct spacing
[20240614_182428]
The bearing block forg…
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