Completed: Fifth scale 2008 F1 car

[Jagboy]

I started working on the front suspension the other day after avoiding it for quite some time. It's definatley been a challenge so far and I haven't figured out much except the general positions of everything. The steering is also going to be a bit of a test to fit in there. The inside distance between the two plates in front is 30mm. The rear suspension is also updated.

[IMG:596:354]http://i14.photobucket.com/albums/a309/ ... ension.jpg[/img]
[IMG:706:453]http://i14.photobucket.com/albums/a309/ ... parent.jpg[/img]
[IMG:603:419]http://i14.photobucket.com/albums/a309/ ... 0_5_06.jpg[/img]


JB

[NickT]

This is the first I have seen of this thread and I am very impressed Jagboy it is really

It looks like you are doing very well, the only comment I have is ask if you are you using standard model parts for the springs, dampers, steering, gearbox, diff, drive shafts and uprights I only ask from the point of view of the ease of making your virtual model into a reality. Manufacturing these items individually could get very expensive where as using existing items will be considerably cheaper and possibly more reliable

Hey it might also free up some cash to fit Ciro's camera

[Jagboy]

The only standard parts as of now are the screws, but evenutally springs, ball pivots, turnbuckles, and gears will be standard. This is a very custom car, so using a standard gearbox or other major components would detract from the overall car. Right now I am not thinking about how much it would cost to build, just about how I can get all of the parts to work together. Once all the parts are there I'll work on it to get manufacturing costs down, but I would have to come into some major money to do anything with it. Thanks for the coment!


JB

[Jagboy]

Well, today was a big day. Two things happened. One: I became satisfied when I realized that over 90% of the components are present. Two: I realized how much work I have to do in order to make it work. The second one is kind of overwhelming, so I'm trying to push that emotion away for a while so that I can get a big enough boost from the first one.

[IMG:800:457]http://i14.photobucket.com/albums/a309/ ... ew1010.jpg[/img]
[IMG:726:512]http://i14.photobucket.com/albums/a309/ ... ly1010.jpg[/img]


JB

[Phoenix]

What program are you using for this project?

[Jagboy]

Solidworks Student Edition 2005-2006. If I get time to analyze it, I'll use COSMOSWorks as well.


JB

[mep]

I still can see a bit of work for you to get this
ready for production.
You get quit big forces with such a big car.
Big gears can handle bigger forces and you need them in the
differential so I think your differential is to smal.
For example the diff I use has 74mm in width from
outside first ball bearing to outside second ball bearing.
So your gearbox has 74mm in width.

At the front you posted that you have 30mm between the two plates in front.
I guess your plates have 10mm at least,
so you haveat the outside 50.
I have here 60mm at a certain point.
This is scale 1:4,5 from the McLaren MP4/20
so you could thake here a bit more to make it original.

I noticed your message and sorry for answering just now.
I will maybe post some pictures later.

[e gaines]

are you using a eletric motor or a nitro motor,an how about a 2 speed.

[Jagboy]

Yeah, I was thinking today about how poorly I designed the gearbox. Now that most of the parts are there, I can revisit certain elements. I plan on doing a total drivetrain redesign today and instead of a solid gearbox I will use the TVPs as mounting spots. The thing I'm struggling with in the differential is the gears. I looked around for some bevel gear geometry diagrams and found some, but they all stated that the best pressure angle is 20*. The diff's diameter is limited to around 70 to 75mm, and that forces the width (when using the 20*) to be very thin. Any suggestions? It would be very easy to make it more durable if 45* angles were used, but would that cause binding?

As for the front width: I made it as thick as I could and still stay within the FIA regs for bodywork between the front wheels. There is a clause that clearly defines the area where no bodywork is allowed and I'm trying to make this as close to a true 1:5 as I can, so I don't have many options there.

I am still using an electric motor. I wish I could do a gas or nitro, but I just don't have the time. A two speed with this motor would be impracital. This motor can have up to around 8kW and enough torque to make a single speed feel significant stress. Multi-speeds work best for IC engines that have drastic, nonlinear torque curves. Electrics don't have that torque curve.

Please keep the technical comments coming. I have limited engineering knowledge and need as much help as I can get. If anyone could point out any helpful literature on the web I would be very grateful. Also, if anyone has any computers or computer parts that are for sale, please contact me as my 4 year old Dell (2.53gHz P4, 1GB ram, old and low end nVidia GeForce MX 420) just doesn't have enough power to handle some of the more complex features of SolidWorks.


JB

[bernif2003]

Hi! congratulations for your design Jagboy, good job . I've got a web where I show my radio controled cars and other projects. Here you can find some information helpfull for you. Actually I'm building the R26 car of Fernando Alonso. Now I have the 3d drawings of the car, and the next step is to calculate some parts. I want to make the chassis with carbone fiber like some other parts of the body.
I hope you like it! thanks!

The link is

http://www.bernimodels.com

[DaveKillens]

This is just a note of encouragement. I'm more a wrench turner than engineer, but I am incredibally impressed with the thought and attention to detail you have displayed. And if it sometimes seem to have run up against difficult things, please remember that right now it's the journey, not the destination that will matter.
It's my honor to witness such an intelligent, young mind doing so well.

[Jagboy]

Thanks for the encouragement. It's people like you and words like that that keep me motivated throughout this project and engineering in general.


JB

[Jagboy]

A new, somewhat innovative differential. Without actually testing it, my guess is that this design would be extremely strong as all of the parts lock together and none of the stress is transfered through screws. This may be a small differential (the outside diameter of the casing is 70mm), but after looking at the Baja 5b (http://www.hpiracing.com/kits/kitMain.php?partNo=10600) differential, this size may prove to be strong enough.

[IMG:565:473]http://i14.photobucket.com/albums/a309/jagboy/Diff2.jpg[/img]
[IMG:530:470]http://i14.photobucket.com/albums/a309/ ... iff2-1.jpg[/img]
[IMG:800:351]http://i14.photobucket.com/albums/a309/ ... iff2-2.jpg[/img]


JB

[Tom]

I like the look of you're driveshaft joints, that is by far the simplest method and CV joints with boots etc are such pains in the arse. Good luck.

[Jagboy]

A reasonably large update:

I got the entire drivetrain and steering reworked. The rear suspension got some important changes such as the utilization of ball joints instead of hinges. There is still much to do, but the end is in sight.

[IMG:761:490]http://i14.photobucket.com/albums/a309/ ... ew1029.jpg[/img]
[IMG:661:421]http://i14.photobucket.com/albums/a309/ ... ks1029.jpg[/img]
[IMG:781:387]http://i14.photobucket.com/albums/a309/ ... od1029.jpg[/img]
[IMG:716:324]http://i14.photobucket.com/albums/a309/ ... ks1029.jpg[/img]
[IMG:753:377]http://i14.photobucket.com/albums/a309/ ... dy1029.jpg[/img]

Feedback is one of the main fuels for this project, so please comment.


JB


PS: If anyone considers themself a SolidWorks expert, please pm me. I am having some trouble with mates and overdefinition.