Ryan Dewey. Mike Persons Dan Persons James Mussehl Nick Traynor Logan Olson Jake Gaines

Transcription

1 07-08 (Concept)

2 Ryan Dewey Mike Persons Dan Persons James Mussehl Nick Traynor Logan Olson Jake Gaines

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4 Log Book Day 1-9/11/07: Today was the first day in our high mileage groups. We picked the foreman and the log book keeper. We started to design the car and ideas for steering and starting the0 car. Day 2-9/12/07: Today we had a short day for class. We couldn t get done as much as we wanted. We did happen to get some measurements down for the frame. We also started our materials list. Day 3-9/13/07: Today was an easy day. With not much to do we could only finish our materials list. We included a motor, barring, and steel rods for our tie-rods and we also included our metals that we needed for our car. Day 4-9/14/07: Today we happened to find an old body from a few years ago. We started to cut it down and keep what we wanted. We also tried to think of ways we could work off of it. We then cleaned it off and made a few adjustment marks to it so that way we could make the car looks better to our likings. Day 5-9/17/07: Today we started cleaning off the paint so we could weld on the frame with a cleaner weld. Also we were still taking some pieces off the body to how we wanted it to look and benefit us. We only removed some of the back and top of the frame. Day 6-9/18/07: Today we started practice welding to see who had the best bead and steady hand. We did this for almost the whole class period. We were trying to see who had the best bead on the aluminum metal sheets so our car would be more stable and hold together longer. Day 7-9/19/07: Today we cut a piece for a cross braces in the car and we were trying to get the angles right so the piece would fit snug between the chassis. This process took us about 1 hour to design and we didn t really finish it all yet. Day 8-9/20/07: Today we are actually welding the piece we cut yesterday to the frame. It was tricky at first because we couldn t get good penetration but eventually we got it to work. Now our car looks sharper and is starting too look done. Day 9-9/21/07: Today is Friday and we cut two more pieces to make the car frame longer. We did this because nick couldn t fit in the car all the way so we need to make a few extensions to the frame. We welded one of the two pieces on and started lining up the second so it could also be welded on.

5 Day 10-9/24/07: Today we started by discussing more ideas for our frame, and how we wanted the car to look. We drew up a few mats and they were all ok. We decided that the longer and slicker frame would work best for us only because we entering a new class that would make some improvements to our school. Day 11-9/25/07: Today was an easy day because we didn t have class because of our homecoming events. Day 12-9/26/07: Mike and Nick went on auto desk, which is a design program we are using for designing our car. We got half the car drawn up. This program was used in CAD classes and which only Nick had took and no one else knew how to work it. Day 13-9/27/07: Again we all worked on the car design, designing the second half. Mike started dimensioning the car after he was done designing. He got so of the dimensions to the front and back half of the car frame. Day 14-9/28/07: We worked on the car design again and Michael finished dimensioning. This took us a little time to sit down and learn the steps in CAD. After mike finished the dimensions we started to work on the frame to the car. Day 15-10/1/07: Today nick welded on another piece to the front of the car. Then we grinded the welds down. He kind of messed up on some of the weld and we had to cut them off and remake some of them, but this wasn t a problem because we need to remake them anyways. Day 16-10/2/07: Today we started to finish wielding the front half of the frame and clean up on the welds with the grinder. The car is starting to get a nice look to it and now we can start building the top half of the frame. Day 17-10/3/07: Today we finished the front-end of the frame and now we started to work on the top half of the frame. So far we have only got the steering mount all set up and tomorrow we will be working on the bars that hold the frame together. Day 18-10/4/07: Today we finally finished the front half of the frame and we ground all the welds down and started to test them. Good news is that only 2 welds cracked and now we have fixed that and will be moving on to our next task. Day 19-10/5/07: Today we started to put the back rest together and so far so good. We will be working on this for the whole class period today because it has a lot of measurements involved with it. We also started to put tack welds on it and tomorrow we will be trying to finish up on that portion of the car. Day 20-10/8/07: Today we finished grinding up the aluminum for the back rest and welded it on. Using the aluminum wheel grinder, we grinded down little spots on the

6 metal to get a good clean weld. After that the back rest was ready to get welded up, we welded and did the best we could to get a good clean weld. Day 21-10/9/07: Today our foremen and log book keepers had a meeting with Mr. Dewey about the progress on both the log book and the car. After talking with Mr. Dewey, we worked more on the back of the frame. Day 22-10/10/07: Today was a short day because of early release, so we didn t have a lot of class time to work. We did have enough time to start cleaning up the frame using the portable wire grinder. We also thought of different ideas for the roll bar. Day 23-10/11/07: Today we worked more on the roll bar and how to get our idea to work. We still have got the right idea towards the roll bar. All we know is that we need 375lbs which needs to be held by our bar. Day 24-10/12/07: Today we grinded the ends of the square tubing that we are using for the roll bar, and got the three pieces welded together. This is also the top part of our frame and we had to reinforce it so that way it could hold 375lbs. Day 25-10/15/07: Today we started by welding the roll bar to the back of the frame. Then we welded the caps to the frame where the roll bar and the frame meet. Day 26-10/16/07: Today we started by grinding down the welds we did yesterday, because we wanted to have a better, cleaner looking weld. Then we re-welded the caps to get a better looking weld. Day 27-10/17/07: Today we started by taking measurements of the frame to try and figure out the placement of the side rails. We also discussed where we are putting the steering wheel. We also talked about how and where we are going to put the steering system. Day 28-10/18/07: Today we worked more on the steering of the car. We started by filing down the hole we drilled yesterday. Then we welded the bushing inside the hole we drilled. Day 29-10/19/07: Today we finished welding the bushing inside the hole we drilled. Then we started figuring out the height where we want to put the axle and steering. Day 30-10/22/07: Today we worked more on the steering for our car. Also, Mike grinded down the steering connectors. We are still trying to figure out how to make our steering work.

7 Day 31-10/23/07: Today we used the lathe to mill out new caster plates for the steering of the car. We also got more welding done to the frame. We started welding the side rails of the frame. Day 32-10/24/07: Today we had to grind down the top of the caster plates, and find the center so we could weld the front axle to the plate. Day 33-10/25/07: Today we didn t get much done on our car because we had a class discussion about HMV events that we could possibly participate in. After the discussion, both welders were being used, so we couldn t do anything. Day 34-10/26/07: Today we got to finish welding the supports for the steering column. Then James used the wire wheel to clean the tubing so we could attach the steering column to the supports. Day 35-10/29/07: Today we cut braces to connect to the supports and the steering column. Then we used the grinder to grind the surface of the tubing so we could weld them to the frame. Day 36-10/30/07: Today we had a class discussion about our progress on each of our vehicles. We also talked more about the HMV events that we are planning on participating in. Day 37-10/31/07: Today we finished grinding the pieces for our braces. Then we started to tack the braces onto the frame. Day 38-11/1/07: Today we finished tacking the braces to the frame; then we started to weld them. After welding them we had to grind down some of the welds. Day 39-11/2/07: Today we started by cutting some aluminum square tubing for the side rails of the frame. Then we grinded down the ends so we could weld. Day 40-11/5/07: Today Mr. Dewey told us that he found out from Briggs and Stratton that we could use an ethanol engine, but we have to make modifications to the motor or it probably won t last very long. Day 41-11/6/07: Today we started by fitting the side rails to the frame. Then we tacked them in place. After we got them to fit the way we wanted, we finished by welding them to the frame. Day 42-11/7/07: Today we cut off one of the caster plates because it wasn t welded on straight. We also grinded down the welds from yesterday.

8 Day 43-11/8/07: Today we had to cut off the braces connected to the front cross member. We had to cut it off because after welding the braces on, the front cross member was beginning to warp. Day 44-11/9/07: Today we did some grinding on the frame where we cut the braces off. We had to measure the distance between the frame and the axle, and we figured out the angle we need to cut them at. Day 45-11/12/07: Today we cut the pieces shorter so they would fit between the frame and axle. Then we grinded the edges down so we will be ready to weld. Day 46-11/13/07: Today, first we grinded the end down on the brace for the right side of the frame because it was too long. Then we tacked the braces to the frame. Day 47-11/14/07: Today, we had to finish up the front end of the frame by welding the braces completely to the frame. We added this part to the car because it would benefit out drive in space and comfort. Day 48-11/15/07: Today, we grinded the front end of the frame only because we needed it to look sharp and plus we had to remove all of the old paint on it. That is for our new paint job that we will be applying at the end of the term which would be about show time. Day 49-11/16/07: Today, we didn t do anything because we only had 2 group members. It was hunting season and everyone but 2 group members we still here. Day 50-11/19/07: Today, Mike was the only person in our group because the rest of us were out of school for hunting. Day 51-11/20/07: Today, again Mike was the only person in our group because the rest of us were hunting. Day 52-11/26/07: Today, Mike, and James started working on the steering of the car. They were trying to make it the most efficient and more durable. They made just a few adjustments to the steering which would include the quick release that would make the more easy to get out of. Day 53-11/27/07: Today, Mike, and Danny started milling out the aluminum piece for the quick release of the steering. Day 54-11/28/07: Today Mike worked more on the quick release for the steering. He used the lathe to make the aluminum tube for the quick release. He was using 1/4inch bit all the way up to ¾ drill bit. This took him about 3 class periods which would also be 3 hours.

9 Day 55-11/29/07: Today Mike and James finished the milling process of the quick release for the steering. Nick and Danny started welding the caster plates back on to the frame. We had to remove them because they weren t welded on to the frame straight. Day 56-11/30/07: Today Mike finished up the quick release for our steering. James started working on a piece for the tie rods. Nick and Danny worked more on the caster plates. Yesterday they got the right one tacked on and today they got the left one tacked on. Day 57-12/3/07: Today Danny and Mike worked on the quick release and steering rod. When they were welding it, they found out they had melted the bushing that is in the quick release. They had to take it apart, and then make a new bushing to replace the melted one. James tapped a piece to hold the steering rod in place. Day 58-12/4/07: Today Mike started milling out the second pair of caster plates for the axle and steering. We also had to start making another quick release and steering rod because the quick release was bent and twisted. We don t know how it happened, or who is responsible, but now we have to make another one. Day 59-12/5/07: Today we didn t have any class time because we had finals for other classes. Day 60-12/6/07: Today we had our final for HMV. Then Mike and I worked on the second quick release for the steering because we have to replace the old one that somehow got bent and twisted. Day 61-12/10/07: Today was the first day of the second term. Today we found out we have two students added to our class, Jake is one of them who is in our group. Nick and I welded the caster plates on the frame, because they were only tacked. Mike and Danny worked some more on the quick release. Nick and Jake also rounded edges on some pieces for the front end of our car. Day 62-12/11/07: Today Mike finished milling the new quick release for the steering system. Mike also made the new quick sturdier and also more durable. Jake and Nick started making the steering wheel and got it welded together, and complete. Day 63-12/12/07: Today Jake and Nick worked more on the steering system, by welding the steering wheel to the steering rod. Mike and James worked on the quick release system by drawing up the plans and mats. Day 64-12/13/07: Today Mike and Nick worked more on the steering of the car. Mike drilled a hole in the quick release for a pin. Nick started working on the supports for the steering rods. Danny mounted the quick release for the tires onto the caster plates. We

10 didn t have to make new ones because they are the ones that were used last year, and the fit our caster plates. Day 65-12/14/07: Today Nick and Jake had to drill a bigger hole in the quick release because the pin didn t quite fit in the first hole. James milled the tie rod plates to try and make them all the same size. Day 66-12/17/07: Today Mike and James drilled the holes in the quick release spindles. They also made the two quick release brackets look sharper by cleaning them up with the file, and the bench brush grinder. Day 67-12/18/07: Today Jake and Nick finished up with the release for the steering system and made it more sturdy with less slack. Mike and James finished drilling holes in our wheel release mounts and cleaned them up. Day 68-12/19/07: Today all of our group members got together and came up with ideas for our front end. Mike and Dan fabricated some wires and aluminum rods as more ideas for our front end. Day 69-12/20/07: Today Mike, Dan, and Nick started working on the universal joints for the car. Day 70-12/21/07: Today we didn t get any work done on the car because it was early release also it is the last day before Christmas vacation, so the class had a pizza party to celebrate. Day 71-1/2/08: Today Mike, James, and Dan started working on the front end of our chassis. They cut some solid aluminum round stock, and welded them together, to start the basic form of the front end. Then Danny started milling out the u-joints for the steering. Day 72-1/3/08: Today the group worked some more on cutting and welding pieces of solid aluminum round stock to the frame to add to the front end of our frame. Day 73-1/4/08: Today the group worked more on the front end of the frame by welding more pieces on. Day 74-1/7/08: Today Mike and Danny started working on the wheel-chair hubs for the car. Jake started looking online for a place that we could buy our engine from. Day 75-1/8/08: Today Mike and Danny looked more for some engines, and phone numbers for dealers. Also Jake called a few of the numbers that they found to ask about some engines.

11 Day 76-1/9/08: Today was early release so we didn t get very much done. James did get a few pieces of aluminum grinded up and ready to be welded. Day 77-1/10/08: Today the group cut four pieces of square tubing to weld to the side rails of the frame. After getting all four pieces welded we started to clean up the metal with the portable wire wheel. Day 78-1/11/08: Today we finished grinding and cleaning the frame with the portable wire wheel. Day 79-1/14/08: Today tried again to find a motor for our car. We are still planning on getting a Honda motor, but we still haven t found one. We are looking at the four stroke series, this is a diagram of the engine. Day 80-1/15/08: Today we worked on the roll bar for the frame of our car. First we welded a plate on the back side of the back rest. Next we bent a piece of solid aluminum round stock for the bar. Day 81-1/16/08: Today we welded the aluminum roll bar to the back of our frame. After that we didn t get to work much because we need to order some more parts. Day 82-1/17/08: Today Mike and James looked online some more to see if we could track down a motor to buy, that would be able to run on the alternative fuel, ethanol. Day 83-1/18/08: Today Mike and Danny took the axel plates off the old frame and grinded them down and cleaned them up with the portable wire wheel. Day 84-1/21/08: Today we started to work on the canopy for our car. Day 85-1/22/08: Today we added on to the back of our frame, so we will have room to mount the motor. Day 86-1/23/08: Today we added some more frame supports to the rear end of the frame for the engine and tire.

12 Day 87-1/23/08: Today Mike started working on the steering box supports for the steering system of our car. Day 88-1/24/08: Today mike, James, and nick started to work on the backrest of the car. They made supports for the engine so that way we wouldn t have to worry about the engine warping the frame. Mike and James worked on the quick release system for the front half of the car. They got one of the two releases done. Day 89-1/25/08: Today Mike worked more on the tire mounts for the back end of the frame. We also wrote a letter to Northwest Honda asking for a donation of an engine for our car. We wrote the letter to the new owner Dan Double. We Hope to get the Honda GX 100 OHV horizontal shaft engine Day 90-1/28/08: Today Mike and James worked on the steering brackets. Mike welded it together, and James filed the holes old. Day 91-1/31/08: We haven t been able to work on our car for the last two days because we had snow days. Today we had only a half hour to work due to winter carnival. James and Nick did have enough time to do a little work on the back end of the frame. Day 92-2/1/08: Today the group worked more on the rear end of our frame by adding tire supports. The new supports extend from the top of the back rest to where the engine will be mounted. Day 93-2/4/08: Today Mike started milling out the spacers for the steering boxes. For the spacer he used solid aluminum round stock and used the lathe to drill out the inside. Also, James worked more on the rear of the frame by adding tire supports to make the frame stronger. Day 94-2/5/08: Today Mike worked some more on the spacers for the steering boxes. Also James and Nick started welding the square tubing to the rear of the car for tire supports. Day 95-2/6/08: Today Mike and Danny started cutting out some aluminum sheet metal for the bottom of the car. They traced out the frame then cut it out using the electric sheer. Day 96-2/7/08: Today Mike and Logan attached the aluminum sheet metal to the bottom of the car using rivets. Then James welded a brace into the back rest. Also James ordered the tires for our car from DT Swiss. Day 97-2/8/08: Today Mike, James and Logan finished attaching the rest of the sheet metal to the bottom and started to cut the back rest out to fit on the back rest.

13 Day 98-2/11/08: Today we worked more on fitting the sheet metal to the back rest, and started attaching it using the rivets. Day 99-2/12/08: Today finished up working on attaching the sheet metal, and eventually we got it all riveted to the frame. Day 100-2/13/08: Today Mike drilled holes for the piece that holds the tie rods to the steering box. James cut the tie rods, and started threading them. Jake started working on the design idea, which is shark fins, which go over the rear tire and engine. Day 101-2/14/08: Today Mike got the tie rods threaded for the steering. Jake worked more on the shark fins for the back of the car. Day 102-2/15/08: Today Mike got the steering rods connected to the holders. Then we worked on getting the alignment of the tires straight. Day 103-2/18/08: Today Mike and Danny got the piece that holds the tie rods and steering box together tacked together. Day 104-2/19/08: Today Mike and James finished welding the piece that holds the tie rods and steering box together, so now the tires are aligned straight. Then we thought about ideas to make the steering work better. Day 105-2/20/08: Today we worked some more on the steering of the car. We tested the alignment and steering of the car out in the hallway. We welded one piece of aluminum on each side of the axle to stop the tires from turning too far. Day 106-2/21/08: Today we started working on the canopy for the car. We got the frame for it mostly welded together. It is welded to the cross brace that the steering column goes to, and it extends to the back rest. It will be made to open side ways instead of forward. It will open from the left side and fold open to the right. Day 107-2/22/08: Today we worked more on the canopy. We had to start over however, because Mr. Dewey didn t approve of the first one. Mike and Nick got the piece for the back of the canopy cut and bent to fit in place. Danny and Logan worked on the front end of the canopy, they got the pieces connected on one side, but we ran out of gas and couldn t weld the second side. Day 108-2/25/08: Today the team worked more on the canopy of the car. We got the main frame welded together, now we are starting to add braces. Jake worked more on the shark fins for the back of the car. He also had to start over because the aluminum rods he used before were not the right thickness.

14 Day 109-2/26/08: Today we worked more on the canopy; we got the hinges riveted to the frame. We also started working rear canopy that goes over the tire and engine. Day 110-2/27/08: Today Danny, Mike, and Nick worked more on the rear canopy. They also welded two supports to the back of the roll bar. Then Jake and Logan took apart the front canopy from last year s car to get some aluminum for a second shark fin that will go above the drive train on the rear of the car. Day 111-2/27/08: Today our Honda GX 100 OHV engine was delivered. James cut a piece of aluminum sheet metal that will be used for the motor mount. Then he drilled holes for the bolts that will attach the motor to the plate. We also put some gas in the motor and got it running. Day 112-2/27/08: Today the team worked more on the rear canopy of the car. We added more supports, and added the second shark fin above the tire. Day 113-3/3/08: Today we mounted the motor to the frame. Then we found the throttle cable we needed. Day 114-3/4/08: Today we welded the new engine plate to the frame, which the motor will be mounted to. We also got the engine mounted. Day 115-3/5/08: Today we had a short class period because of finals. We started working on the throttle for the car.

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50 Basic vehicle configuration This year we decided to have a concept car because of how many kids were in the class. In this concept car we are planning on running it on an alternative fuel such as ethanol. Since our group is new to HMV we decided to use an old frame and fabricated it to fit our needs. It didn t take us long to catch on to aluminum welding. We started to build the car by coming up with some dimensions, which were based on our drivers size. Most of the car s layout was based off what had worked in the past and how it would apply to our drivers comfort. We want our car to just fit our driver to stay light and aerodynamic. As we built the frame we took the back half off the old stock car and then we stripped the old back frame down. We then used the scrap metal and began to design the angle for our drivers back to rest on. After we found the right angle we added a few feet onto the front frame and welded it on to suit our driver. We used 1 ¼ square tubing for the whole frame. Our car was officially done for the bottom portion of the frame. We then started to add the top part of the frame on and finished that in a single day. We used the same type of stock for the top half and we completed the entire front portion of the frame. With our frame almost done we started working on the steering which brought a lot of controversy among the group, because of never being in HMV before. We looked at past years and saw how they were able to make their steering. We agreed that box steering with quick releases would be the best way to go. This would allow use to have smooth cornering during the race.

51 The box steering was built out of square tubing that was 3 inches wide and was 1/8inch thick. After that was cut, we designed a piece of aluminum that would stick out for the quick release to slip into. This plate was made out of 1/4inch flat stock and was welded onto the aluminum square tubing. With the steering and front portion of the frame done, we began to work on the back half of the frame. We made the back frame at a 45 degree angle and use 1 ¼ inch stock. As we began to finish the back portion of the frame we began to notice a problem. The bars on the back had warped inwards after welding, so we had to bend them out. As we began to fix all the problems we began to notice that our car would look very sharp out on the road. Now it was time to work on the engine, after talking with some ethanol engineers and small engine mechanics, they suggested we go with a Honda GX 100 OHV horizontal shaft engine. Once that was figured out we decided to go with a chain drive. This was because we were told that they ran cone drives in the past, but didn t do so well when it slipped due to weather. That ended up causing the tires to wear down. Now that our power train was set we moved to covering the cars. We had the cars sandblasted so that way our new fresh coats of paint would stick so much better and we began to build our canopies. The canopies consist of 1/4inch round stock and we build around the frame to get the basic look. After we built around the frame we started to design our own look for the car. Due to all of these different components that make up our concept High Mileage Vehicle car we hope to be able to complete at the top this year at Stout.

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53 Power Train Configuration Power train : a train of gears and shafting transmitting power form an engine, motor, etc, to a mechanism being driven. Without the existence of the power train, our vehicle would lack the ability to move on its own power. A power train is defined as a system that gives the car its power to perform. Most commonly, it is made up of an engine that provides power and a transmission that transfers that power to the wheels. Our engine is a Honda GX100 1½ horsepower engine. It will supply power to the rear wheel of the car through a chain driven system and sprocket. The clutch we are using for our Honda engine will idle at 2000rpm and engage at 2500rpm, giving us the desired performance. As the crankshaft of our engine rotates the clutch engages at 2500rpm, which then engages the chain. The chain is wrapped around the clutch and rear sprocket, which is fixed to the rear tire. The clutch and the sprocket are joined together by the chain creating a constant pattern of motion. From there the power is transferred through the chain to the large sprocket causing the tire to rotate, which gives us our forward propulsion.

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55 This year we decided that we would stray away from the traditional braking system that we have used on the stock car in the past. Instead we are using a disc brake system, which has proven superior on our modified car in recent years. The brake handle is located on the left side of the steering bar, which is located in the center of the car directly in front of the driver. We have made sure that the brake handle will not be a problem in turning the steering bar as well as that there is enough cable protruding from the frame so our flip up steering column is still able to be of use to us. Our brake cable was run through back to the rear to the caliper. brake pads and a brake handle is the car the brake securely fixed to the aluminum frame and wheel, where it is attached The caliper consists of two lever system. When the squeezed by the driver of cable is pulled which is the lever of the caliper. As the caliper is pulled back the brake pads are squeezed together against the rotor which is attached directly to the tire, causing the tire too decrease its speed gradually and stop its forward motion. However, if the brake lever is squeezed to quickly, the rear tire will lock up causing an unwanted flat spot on the tire. This will create great amounts of heat due to friction. However, because of the slots machined into the rotor the amount of heat will be

56 reduced greatly. Due to these aspects of the disc brake system we expect that we will be able to stop within the required 25 feet braking distance with no trouble what-so-ever.

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58 Vehicle safety items Kill Switch: There are two kill switches, one mounted on the inside of the vehicle. One is next to the throttle and the other is on the outside of the vehicle. The two kill switches are easily accessible to the drive, pit crew, or the judge. A simple flick of the toggle switch will kill the vehicle. Guards and Shields: all moving parts on the car are covered, or shielded by a frame, or sub frame. This will protect people who are working with and around the vehicle. Helmet: we are using a open face DOT type approved helmet which has goggles to protect the drivers eyes from any foreign object that might come in contact with the eyes. Fire Extinguisher: we have a three-pound multi-purpose (ABC) dry chemical fire extinguisher. It is located between the legs of the driver on the inside of the car. Seat Belts: the car contains a three-point seat belt mounted directly to the frame by three ¼ inch bolts. The belt comes over the shoulder, and over the waist keeping the driver inside the car in case of a rollover. Roll Bar: a roll bar is attached to the frame close to the rear of the car. The top of the roll bar is six to eight inches above the head of the driver. This will keep the driver safe incase of a roll over. It is also designed to stop the car from rolling over repeated times. Fuel and Lubricant Line Clamps: Fuel and lubricant lines are securely clamped underneath the engine compartment. There is a clamp on the engine and a clamp on the frame for the fuel line. The lubricant is fully contained in the crankcase; therefore it does not require the use of any sort of clamps. Enclosed engine Compartment: The engine compartment is constructed of monokote spread over an aluminum frame. It will cover a large portion of the rear tire along with the engine. Mirrors: the mirrors will be velcrowed to the top bars on the steering system. These mirrors have been adjusted to the driver to allow for a maximum field of vision.

59 Firewall: The firewall is made of.05 thickness aluminum, which is riveted securely to the frame of the car. Exhaust system exit: The exhaust pipe has been lengthened to the appropriate length, which is according to the specifications of the car, and has been positioned so as it will exit the rear of the engine compartment on the drivers right side. Floor pan: Just as the firewall the floor pan is made of.05 thickness aluminum, which is securely riveted to the bottom of the frame to allow no gaps and that it is sturdy enough to serve its purpose.

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61 Problem Solving Essay Team Concept Throughout this class, our team has had some obstacles that we had to overcome. Being the first concept team at Chetek, we had some big challenges to face. We wanted to use an alternative fuel this year, so we decided to use ethanol for our fuel. We are planning to have our chemistry class make the fuel for us. We also needed to find an engine for our car that was compatible with the ethanol fuel. This would be a long process because we needed to look up all the specs for the engines and make sure they are capable of taking a alternative fuel. We choose the Honda GX 100 OHV horizontal shaft engine because we called up the company and they suggested it. This year s car was slightly difficult to build, but everyone on the team helped each other to solve the challenges. We wanted to follow the design of our previous stock car, so that made the job easier right away. Many things we made had minor flaws or problems but we learned we had to fix them and move on. Some of are biggest problems were when we tried to figure out the best options for the car. Some of the ideas we tried didn t work out as planned so we had to always think of a backup solution to the problem. The problem solving process is more or less defined by the following steps: Define the problem, Establish your goal, Come up with past ideas, Brainstorm, Pick the best solution, come up with a model, test, and make changes if needed. Here are some of the key problem things that we came up with.

62 Some of our problems where bigger than others like at the start of the year we didn t know what design we wanted for are concept car. So we had to sit down and sketch out our ideas on paper but nothing seemed to work. One of our first problems was to figure out size of the car. We knew what we wanted for a design, but not a size. When we thought of whom the driver would be, it came to us a lot easier. Our driver Nick is somewhat smaller, so we thought our frame design wouldn t have to be all that big. Therefore, we started drawing out new plans and figured that the car would be small, light, and very compact. We figured that because of his small size and weight, we could make this vehicle lower to the ground. This would give us less clearance, but more of a lower center of gravity. We then sketched out the dimensions and got passed the design problem within in a few days time. Another thing that we didn t have for the car was a sprocket. We had decided to switch to all three cars being chain driven this year. In the past we had cone driven cars and weather and traction made it hard for them to operate at their highest potential. We decided to make the sprocket the same size as the one for our modified and stock car. Since this one seemed to work well last year, we wanted to try it again. The steering tie rods ended up being a problem for us also because our design made the tires operate backwards. Once we finished setting up the steering for the first time, it looked good. We took the car out into the hall and pushed it down the hall to test it. Unfortunately, we had the steering set back wards. It was so tough that it made the car to hard to handle. So we fixed our steering up so that way we wouldn t be in a world of pain. We also had some problems with stability in the steering. So we weren t sure if we d be able to get rid of the wobble, but we knew we had to try. We started by moving

63 the center point of the steering rods to see if that would help. We tried the car again and it worked a lot better but the steering over turned so we couldn t turn it back the other way. This time we put stoppers between the tie rods and frame so it wouldn t turn so much.. One of our biggest challenges was making a new canopy for the concept car. In past years they have used Lexan plastic and made a frame out of aluminum to make it sturdy. This year we wanted to try and do something different. We wanted to get away from using the aluminum framing to give it a more streamline look. We were also trying to make the car lighter and this was a way to save weight. Looking at some pictures of other teams from the past, they were able to use plain plastic without the metal frame. We came up with some ideas of cutting pieces of plastic together and trying to glue them. We also thought of making hinged pieces, but after thought we came to the conclusion that that would be too weak. We found that just taking regular Plexiglas just didn t work well for us either. So, we contacted a business in our town called Turbine Technologies because they do a lot of fabrication work. They told us that we should try using polycarbonate sheeting, so that we can bend and form the canopy to our desired design. We made a call to a supplier and they sent us a supply of polycarbonate samples. We took a sample that was smaller than what we needed, bent it to the angles we wanted and adjusted it to the car. Even though it was a smaller piece we decided that this was definitely an option for making our canopy. In conclusion, even though we ran into some problems with our car, we worked through it and as a team we worked out those problems. All it took was some minor

64 adjustments and thinking between all of us. That is how we accomplished finishing the concept car.

65 School Participating: Advisor: Supermileage Proposal Packet Evaluation Instrument A. Log Book 1. Overview of the Problem Solving Process (e.g., analysis of the problem, defining the problem, specifying a solution to the problem, gathering information regarding the problem, generating alternative solutions to the problem, developing the optimal solution to the problem, specifying the solution to the problem, building a prototype solution to the problem, evaluating the solution to the problem, reporting the results to others) The log book includes The log book contains Approximately half of Only a few of the steps entries for at least eight entries for most of the the steps commonly associated with problem of the steps illustrated steps associated with associated with problem solving are represented in the rules packet (p.4). the problem solving cycle. solving have entries. in the log book. 2. Gathering the information needed to solve the problem. 4 pts. 3 pts. 2 pts. 1 pt. The log book includes The log book contains The log book features The log book only at least 4 references that less than 4 references at least 4 references but contains one or two address a variety of but they address a they all address one or references about a issues related to building variety of issues related two aspects of building a limited number of topics a fuel efficient vehicle. to building a vehicle. fuel efficient vehicle. related to a vehicle. 3. Gathering the information needed to solve the problem. 4 pts. 3 pts. 2 pts. 1 pt. The thumbnails feature The thumbnails illustrate The thumbnails feature The thumbnails feature at least 5 sketches a variety of ideas for at least 5 sketches less than 5 sketches representing at least 5 building the car with less representing variations illustrating a modest different approaches to than 5 sketches and approaches on one or two approaches to number (less than 5) of building the car. to building the car. building the car. strategies for building a car.

66 4. Calculations (e.g., mechanical advantage associated with various drive train scenarios, linear distance traveled per engine revolution, center of gravity based on ground clearance and weight distribution, mean vehicle performance based on multiple trial runs, projected miles per gallon at UW-Stout based on vehicle performance data over shorter test runs). 4 pts. 3 pts. 2 pts. 1 pt. The log book includes The log book includes a The log book only reports The log book reports detailed calculations that detailed calculations to the results of calculations the results of calculations support at least 2 design inform one design decision. That supported 2 or more that are related to one decisions. design decisions. aspect of the car. 5. Daily Log (e.g., meetings, fund raising activities, goals, accomplishments, problems, resources, expenses, participant responsibilities, decisions, questions, milestones, deadlines). 4 pts. 3 pts. 2 pts. 1 pt. The log book features The log book includes a The log book lists The log book features frequent and detailed regular pattern of brief notes periodic and short notes spotty and vague references anecdotal records that describing key events and regarding notable events to a modest number of document a wide range decisions in the development and activities in the design events in the design and of variables associated of a vehicle. and construction of a vehicle. building of a vehicle. with building a vehicle. 6. Cost Estimates Time Estimates. 2 pts. 1 pt. 2 pts. 1 pt. The log book includes The log book contains some The log book includes a The log book includes a a comprehensive budget budgetary information regarding time line outlining the modest schedule of key for the design, development the projected expenses associated important milestones and activities associated with and testing of the vehicle as with building a vehicle and/or developmental steps in the the design, building and well as participating in the entering in the challenge. design, financing, building testing of a vehicle. Supermileage challenge. and testing of a vehicle.

67 B. Basic Vehicle Configuration 1. Written description of the vehicle (e.g., propulsion, directional control, chassis, body, drive train). 4 pts. 3 pts. 2 pts. 1 pts. The proposal packet features The proposal packet includes The proposal packet contains The proposal packet includes a narrative that provides a a narrative that describes some a general description of some a modest paragraph that comprehensive and detailed of the prominent features of the of the vehicle s features without provides a vague and incomplete description of the vehicle s vehicle in some detail. An attention to important description of the vehicle features. important features and systems. details. 2. Drawing of the vehicle (including role bar). 4 pts. 3 pts. 2 pts. 1 pts. The proposal packet includes The proposal packet includes The proposal packet contains The proposal packet features multiview and detailed drawings that illustrates the simple technical drawings that concept drawings that include drawings that illustrate and vehicle s prominent features but feature some important a few general dimensions but dimension the size, shape and the dimensions are incomplete. dimensions but generally lack do not include important location of important vehicle significant details. technical details. features. C. Power Train Configuration 1. Written description of the Power Train (e.g., engine, clutch, energy transmission system, drive wheel). 4 pts. 3 pts. 2 pts. 1 pts. The proposal packet features The proposal packet includes The proposal packet contains The proposal packet includes a narrative that provides a a narrative that describes some a narrative that describes some a short, vague and incomplete comprehensive and detailed of the important features of the of the features of the vehicle s paragraph that describes the description of the vehicle s vehicle s drive train. drive train. vehicle s drive train. drive train.

68 2. Drawings of the Power Train. 4 pts. 3 pts. 2 pts. 1 pts. The proposal packet includes The proposal packet includes The proposal packet contains The proposal packet features multiview and detailed drawings drawings that illustrates the simple technical drawings that only concept drawings for the that illustrate and dimension the vehicle s drive train but the feature some of the important vehicle s drive train without size, shape and location of dimensions and specifications features of the vehicle s drive giving attention to important important vehicle features. are incomplete train. technical details. D. Performance 1. Description of the Tests Performed. 4 pts. 3 pts. 2 pts. 1 pts. The proposal packet features The proposal packet includes The proposal packet contains The proposal packet includes a narrative that provides a a narrative that describes some a narrative that describes some a short, vague and incomplete comprehensive and detailed of the important features of the of the features of the vehicle paragraph that describes the description of the vehicle important features of the vehicle testing process. vehicle testing process. testing process. testing process. 2. Presentation of the Date Gathered. 4 pts. 3 pts. 2 pts. 1 pts. The proposal packet reports hard The proposal packet presents the The proposal packet simply The proposal packet lists the data based on multiple vehicle data gathered from multiple tests reports the results of a modest findings of a teat in a simplistic tests using appropriate tables in simple tables or graphs that number of tests in tables or or incomplete format that is very and/or graphs that are easy to require study and interpretation. graphs that require some difficult to understand. understand. explanation. 3. Conclusions and Recommendations. 4 pts. 3 pts. 2 pts. 1 pts. The testing process resulted in The testing process resulted The testing Process inspired The testing and refinement at least 2 conclusions, based on in one or more conclusions modifications to enhance the process was very random and data, and 2 recommendations based on data that inspired vehicle s performance based on based more on trial and error for improving the vehicle s an adjustment to improve intuition and guess work more than conclusions based on hard performance. the vehicle s performance that hard data. data.

69 E. Braking System 4. Written Description of the Braking System. 4 pts. 3 pts. 2 pts. 1 pts. The proposal packet features The proposal packet includes a The proposal packet contains a The proposal packet includes a a narrative that provides a narrative that describes some of narrative that describes some of short, vague and incomplete paracomprehensive and detailed the important features of the the features of the vehicle s graph that describes the vehicle s description of the vehicle s vehicle s braking system. braking system. braking system. braking system. 5. Drawings of the Braking System. 4 pts. 3 pts. 2 pts. 1 pts. The proposal packet includes The proposal packet includes The proposal packet contains The proposal packet features multi-view and detailed drawings drawings that illustrate the vehicle s simple technical drawings that only concept drawings for the that illustrate and dimension the braking system but the dimensions feature some of the important vehicle s braking system without size, shape and location of the and specifications are incomplete. Features of the vehicle s braking addressing important technical vehicle braking system. system. details. F. Problem Solving Essay 1. Reflection, Insights & Lessons Learned. 3pts. 2 pts. 1pt. The problem solving essay is a rich and The problem solving essay reports The problem solving essay is simply a detailed narrative that looks back on the what was done, identifies something report of what was done and does not design process, discloses 2 or more lessons that was learned from the process and provide any evidence of growth nor does that were learned, and offers words for provides a suggestion for those who it offer any insights for those who will wisdom for the next team. participate in the challenge next year. take over the project. 2. Editing and Readability. 3pts. 2 pts. 1pt. The problem solving essay is free of The problem solving essay is technically The problem solving essay is very rough grammatical errors and it exemplifies accurate but it could be edited to enhance and with major grammatical flaws requiring clarity, brevity, and focus. its communication value. several readings.

70 G. Safety Items (checklist) The proposal packet includes drawings and specifications that illustrates and describes: 1. two kill switches that ground the engine s ignition system. kill switches being of ½ inch toggle type. kill switches being marked by a 2 or greater diameter florescent orange marker tag. one kill switch being mounted within reach of the driver. one kill switch being mounted to easy accessibility from the vehicle s exterior. 2. guards and shields that protect the driver and/or outside observers from broken drive train components. guards and shields that protect the driver from any interior mounted moving wheels inside the cockpit of the vehicle. 3. the clamps that secure fuel and lubrication lines. the bracket for mounting the fuel bottle. easy accessibility for dismounting the fuel bottle. 4. a braking system that can be activated by the driver. 5. a fire extinguisher that has at least a two pound rating. the fire extinguisher also being rated for multipurpose use or ABC. a mounting system that allows for easy access for the driver. 6. an exhaust system that exits the vehicle s body. 7. a steel or aluminum fire wall. a minimum thickness of inches for the firewall. full separation between the driver and the engine compartment by the firewall.

71 no openings in the firewall, or compensation for them. the firewall extends beyond any portion of the driver s body. 8. a steel or aluminum floor pan. a minimum thickness of inches for the floor pan. full protection from the underside of the driver. (i.e., from base of firewall to beyond the driver s feet.) 9. two rear view mirrors mounted to the vehicle. 10. a seat belt. 11. a roll bar. a mirror mounted on each, the right and left side of the vehicle. the seat belt consisting of at least three points of fastening to the frame. the seat belt being fastened securely to the frame. a gap of at least 6 inches between the roll bar and the driver s helmet. 12. an enclosed vehicle body. a maximum opening area of 2 feet in diameter for the driver s head. 13. an enclosed engine compartment. the engine compartment being fully enclosed to the outside with the exception of directly beneath the engine where the only thing that will come in contact is the ground. H. Evaluator(s): Print 1 Print 2 Signature 1 Signature 2