Open Source Ecology - User contributions [en]

Wikispeed SGT01

2012-07-04T16:41:46Z

Matt Maier: /* From Joe's Notebook */

NOTE- this article is flagged for re-title to "SGT01", for super grant touring 01.

Team Wikispeed has open sourced their first car! They agree with OSE, and the open source movement, that everyone will benefit faster when there are fewer barriers to innovation and collaboration.

It is important to note, however, that the STG01 is not the GVCS car. It was designed to compete in the Progressive Automotive X-prize, not to be made out of the common modular pieces of the GVCS. But the principles/processes are largely the same, and many of the control/interface systems can be identical.

=Wikispeed STG01=

==CAD==

[[image:SGT01 2011 June 28th angle view.gif|thumb]]

The following CAD files are STEP 203's that were exported from the Alibre files Wikispeed uses.

The assembled vehicle (mostly).
* [[File:Wikispeed_SGT01_Assembled.stp]]

Chassis Module
* [[File:Wikispeed_SGT01_Chassis.stp]]
<gallery>
image:Wikispeed_SGT01_Chassis.jpeg
</gallery>

Bulkhead Plate
* Attaches to the front of the chassis
* Used to mount things like the brake cylinder
* [[File:Wikispeed_SGT01_Bulkhead_Plate.stp]]
<gallery>
image:Wikispeed_SGT01_Bulkhead_Plate.jpeg
</gallery>

Engine Module Frame
* [[File:Wikispeed_SGT01_Engine_Module_Frame.stp]]
<gallery>
image:Wikispeed_SGT01_Engine_Module_Frame.jpeg
</gallery>

Floor Plate
* Attaches to the bottom of the chassis
* [[File:Wikispeed_SGT01_Floor_Plate.stp]]
<gallery>
image:Wikispeed_SGT01_Floor_Plate.jpeg
</gallery>

Crush Structures
* Attaches to the front/rear of the chassis
* Serves as a sacrificial crumple zone in the event of a crash
* Used to mount things like headlights
* [[File:Wikispeed_SGT01_Front_Crush_Structure.stp]]
* [[File:Wikispeed_SGT01_Rear_Crush_Structure.stp]]
<gallery>
image:Wikispeed_SGT01_Front_Crush_Structure.jpeg
image:Wikispeed_SGT01_Rear_Crush_Structure.jpeg
</gallery>

Interior Module
* This is the interior module as an aluminum tube frame
* [[File:Wikispeed_SGT01_Interior_Module_Frame.stp]]
* This is the interior module as an aluminum bathtub
* [[File:Wikispeed_SGT01_Interior_Module.stp]]
<gallery>
image:Wikispeed_SGT01_Interior_Module_Frame.jpeg
image:Wikispeed_SGT01_Interior_Module.jpeg
</gallery>

The Assembled Suspension
* [[File:Wikispeed_SGT01_PassSide_Suspension_v3.stp]]
<gallery>
image:Wikispeed_SGT01_PassSide_Suspension_v3.jpeg
</gallery>

Suspension Components
* Tie Rod
* [[File:Wikispeed_SGT01_Suspension_Left_Tie_Rod.stp]]
* Lower Control Arm
* [[File:Wikispeed_SGT01_Suspension_Lower_Control_Arm.stp]]
* Hub pivot point
* [[File:Wikispeed_SGT01_Suspension_Lower_Hub_Pivot_v2.stp]]
* mount plate
* This is what holds the suspension together and attaches it to the chassis
* [[File:Wikispeed_SGT01_Suspension_Mount_Plate.stp]]
* strut mount
* [[File:Wikispeed_SGT01_Suspension_Strut_Top_Mount.stp]]
<gallery>
image:Wikispeed_SGT01_Suspension_Left_Tie_Rod.jpeg
image:Wikispeed_SGT01_Suspension_Lower_Control_Arm.jpeg
image:Wikispeed_SGT01_Suspension_Lower_Hub_Pivot_v2.jpeg
image:Wikispeed_SGT01_Suspension_Mount_Plate.jpeg
image:Wikispeed_SGT01_Suspension_Strut_Top_Mount.jpeg
image:IMG_9876.JPG
image:IMG_9871.JPG
image:IMG_9872.JPG
image:IMG_9867.JPG
image:IMG_9866.JPG
image:IMG_9873.JPG
</gallery>

Body Frame
* This frame mounts any aerodynamic body to the chassis
* [[File:Wiklspeed_SGT01_Body_Module_Mount_Frame.stp]]
<gallery>
image:Wikispeed_SGT01_Body_Module_Mount_Frame.jpeg
</gallery>

==Bill of Materials==

* Chassis ~$434
** 4"x4"x.125" extruded square tube 6061-T6
** brake lines, 28'
** floor 78"x48"

* Engine Module ~$8422 (from Honda Performance Development)
** GENERAL ASSY., CYLINDER BLOCK (DOT)
** GENERAL ASSY., CYLINDER HEAD
** WIRE HARNESS, ENGINE
** ALTERNATOR ASSY. (AHGA67) (MITSUBISHI)
** BRACKET, ALTERNATOR
** 4x4x.125" extruded square tube (140 feet?) 6061-T6
** camshaft, cam chain
** clutch - torque converter
** Catalytic Converter
** Injector Assy, Fuel
** Gasket Kit (engine, transmission, chain case)
** Intake Manifold
** Pump Assy, oil
** plug hole coil
** spool valve
** STARTER MOTOR ASSY(SM-71001)MITSUBA
** Throttle Body 1.8L
** ARM ASSY., ROCKER
** water hose (1.8l)
** water pump (1.8l)
** 5AT Transmission
** 5MT Transmission
** Radiator
** Radiator hose
** ECU 1.8L MT

* Engine Module Least Expensive ~$5232 (Honda Performance Development)
** L15A crate engine
** L15A 5MT
** L15A ECU 5MT
** L15A ignition
** L15A key
** L15A engine harness
** L15A dash harness
** Radiator
** Radiator Fan+shroud+motor
** Radiator hose

* Engine Module More Power ~$8815 (Honda Performance Development)
** Civic Type R crate engine
** Si 6MT
** Hondata ECU
** Civic Si ignition
** Civic Si key
** Civic Si engine harness
** Civic Si dash harness

* Engine Module Frame ~$169 (for 2 units)
** 1.25x1.25x.125" 6061-T6 tube (34.4 feet?)

* Suspension ~$4283 (for 4 units)
** Skunk2 Pro C
** 15x7 MOTEGI RACING SP10 HB
** 195/65R-15 Bridgestone Ecopia EP100
** .25" thick plate, 2'x2' 6061-T6
** strut top mount angle 6061-T6
** 3/8ths x24 grade 8 bolts
** 3/8ths x2 lock nuts
** 1" OD 3/8ths ID steel washers
* (Honda Performance Development)
** Front Knuckle
** Joint F. Ball Lower
** Bearing Assy, Front Hub
** Hub Assy, Front.
** Disk Fr Brake
** Caliper sub assembly, FR
** Pad Set, FR.
** knuckle bolts (BOLT, FLANGE (14X57)) (2)
** knuckle bolt nuts (NUT, SELF-LOCK (14MM)) (2)
** strut top mount nuts (NUT, FLANGE (10MM)) (3)

* Pedal Plate ~$243
** steering column (summit racing)
* (Willwood)
** steering rack
** CMB-14-0010 master cylinder and pedal combo
** ABS block and proportioning valve: WIL-260-11179
** APS229 - Standard Motor Accelerator Pedal Sensors

* Front Crush Zone ~$22
** 6x6x.125" 6061-T6 square tube (9.1 feet?)

* Rear Crush Zone ~$19
** 6x6x.125" 6061-T6 square tube (7.75 feet?)

* Side Crush Zone/Trunk ~$169 (for 2 units)
** 1.25x1.25x.125" 6061-T6 tube (34.4 feet?)

* Body/Aeroshell ~$1107
** polycarbonate (US plastics) (4'x8' x 1/8" sheet)
** nida core honeycomb (NW composits) (4'x8' x 1/2" sheet)
** rivets
* (US Composits)
** 5.7oz Carbon Plain weeve (50" x 18 yards)
** epoxy (54 gal)
** hardner (18 gal)
** 10oz e-glass mat (50" x 18 yards)
** e-glass biaxial mat 1208 (50" x 18 yards)

* Body Top Mount Frame ~$169 (for 2 units)
** 1.25x1.25x.125" 6061-T6 square tube (12.5 feet?)

* Interior ~$823
** carpet 40"x6'
** Autoloc 3 point belt (2)
* (US Composits)
** 5.7oz carbon plain weeve (6)
** epoxy
** hardner
** 10oz e-glass mat (6)
** e-glass biaxial mat 1208 (6)
* (Summit Racing)
** GRT-687 GRANT RACING STEERING WHEEL
** SUM-800600 DIGITAL 6 GAUGE PANEL
** poly seat black 2100 series & cover combo (2)
** DUAL LOCK SLIDING SEAT BRCK PR (2)
** SUM-G1122 COVER & BRACKET KIT SINGLE
** CIP-19100 REPL MIRROR PAIR
** SUM-G2111 seat cover for G2100 seat (2)

* Wikispeedlet ~$271
** 5-1577-4 3.93" STROKE 107 LB. 12 VDC LINEAR A (Surplus Center)
** 5-1577-B LINEAR ACTUATOR MOUNTING BRCKT (Surplus Center)
** Arduino Uno (Maker Shed)
** 12v to 5v converter
** Box, 12"x12"x4".
** PEDAL ASSY., ACCELERATOR (Summit Racing)

* MT Shift Control ~$233
** 5-1577-4 3.93" STROKE 107 LB. 12 VDC LINEAR A
** 5-1577-B LINEAR ACTUATOR MOUNTING BRCKT
** Arduino Uno
** 12v to 5v converter
** Box, 12"x12"x4".

==Chassis==

The Wikispeed car(s) is always evolving, so it's best to start with a piece that hasn't significantly changed in a while. The basic chassis is nothing more than 4" square aluminum extrusion welded into a series of boxes. However, it has a 5-star crash equivalency rating. It is only around $550 in parts and those parts are commodities, so they can be overnighted pretty much anywhere in the world. All you need to build the chassis is an average sized garage, a saw to cut the aluminum, and a welder to fasten it together.

Illustrations are on the way.

BOM
* 4" x 1/8" thick square tube
** 120" long (x4)
** 40" long (x4)
** 12" long (x6)
* Yeah, that's it. That's all the frame is made out of :-)

Project Steps
* Cut aluminum tube to specified lengths
* The only location that needs to be measured
** The center vertical tube is 36" from the inside of the vertical tubes on the open end of the chassis and 72" from the inside of the vertical tubes on the closed end
** Other than that, everything lines up on obvious edges

===From Joe's Notebook===

For the aluminum, we use Coast aluminum over here, and order 500 lbs at a time in stock lengths. This lets us get a discount, and by always ordering whatever length they stock we avoid "cut fee's". For the build, it is ideal to have 3' on each side of parts we are working on. For the chassis, it's 4'x10, so 10'x16' is ideal. The total car, with body, is larger at 6.5'x14', so 12.5'x20' is ideal. It can be worked with far less, however, and I think the ultimate flow of work, when it is optimized, will be to manufacture these inside a shipping container "factory" that can be shipped to wherever the local demand might be.

The jig plates [specifications on the way] are a pre-requite for building the chassis...After each weld, the surface is grounded down (4" electric grinder, or, a coarse file and some hand work) so that the jig plate can be bolted back on flush. At the end, the jig plates are actually other modules- the roll bar mounts and the suspension plates, so they simply have the rest of their components bolted on and now there is a rolling chassis.

Using the jig plates and a 3/8ths centering punch, holes can be drilled to attach the frame to the jig with bolts, then the frame is tack welded, then the jig plates are removed and replaced one corner at a time while the frame is seem welded with the other jigs holding the chassis square as it is heated and cooled during the welding.

The current configuration requires 18.33 KW to bring its 1404 weight plus a 150 lb driver (EPA standard) through the UDDS city test, and 15.11 for the HWFET highway test. However, to meet the X Prize minimums (no-longer required but researched by the X Prize as acceptable minimums for mainstream market interest) our vehicles requires 31.1kw to go from 40mph to 65mph in less than 9 seconds. This is approximately 41.7hp. 50hp or larger gives us a safe target to determine in the drive-train meets our minimums. Please note the current 140hp engine module weighs about 700lbs. That includes fuel, emissions system, cooling system, axles, transmission, engine, engine electronics, data logging, battery, coolant, all fluids, 4 gallons of gas, aluminum engine module cradle.

For brakes, we've used OEM Honda parts and Willwood parts, each had advantages. Currently we are using OEM Honda (2006 civic 1.8l automatic) steering knuckles, bearings, hub carriers, brake rotors, and calipers. Currently we are using a Willwood pedal and master cylinder combo. For steering, currently we are using a honda s2000 steering rack. In past we have used a 2006 civic steering rack. There are pros and cons to each.

...you would need $540 of skunk2 suspension system(normally $1799 but we get a great discount) and some suspension and braking assemblies from a 2006+ 1.8 automatic honda civic. You may be able to get those at a good price from a wrecking yard...

==Build Steps for Small Volume Scenarios==

===Rolling Chassis===

===Chassis===

* receive in mail or cut and weld on location. http://www.youtube.com/watch?v=YvN8ZF1-ogY&context=C4d5a23fADvjVQa1PpcFNIheMStKChcQuO9z0Bcs9fLnn3W5EWwXM=
* cut and weld on location requires bandsaw set to cut square, jig plates (can be mailed or CNC'd locally), speed square and accurate 48" tape measure with 1/16th" or smaller tick marks.
* If made on site, chassis must then be drilled, requires centering punch, hammer, centering 3/8ths drill bit and drill (drill press or coal drill preferred).

===Suspension Module===

* 12 strut top nuts
* 4 Skunk2 Pro C adjustable struts
* 4 brake calipers/pads/bolts
* 8 19mm bolts for knuckles on strut
* 4 lower knuckle ball joints/fasteners/lock nuts
* 32 grade 8 bolts/lock nuts to attach plate to chassis
* 20 lug nuts
* receive in mail or CNC on location.
* Assemble
* compare to photos for test.
* bolt on to car
* recieve grade 8, 3/8" bolts, washers, and lock nuts
* 9/16ths wrench and socket with ratchet required
* compare to photos for test.
* it should be possible to swap out a cheaper strut however, the details are not straight forward. The main problem is that struts are usually pretty tall. The adjustable ones can be lowered, reducing their height by as much as 6" (more or less).

===Wheels & Tires===

* receive wheels with tires and lungnuts in mail (tirerack)
* jack up chassis; set up car jack; put wood block on car jack to avoid scratching frame.
* bolt on wheels; Lug wrench required

===Braking Chassis===

===Pedal Plate===

* receive pedal plate in mail or CNC on location.
* bolt pedal plate onto chassis; recieve grade 8, 3/8" bolts, washers, and lock nuts
* receive brake pedal in mail (willwood)
* receive brake master cylinder in mail (willwood)
* receive accelerator pedal in mail.
* bolt pedals and master cylinder to pre-drilled holes on pedal plate; recieve grade 8, 1/4" bolts, washers, and lock nuts

===Brake Lines===

* receive brake lines in the mail, pre-flared or flare on location; if flaring on location, requires bubble flare tool, metric AND SAE brake line fittings.
* bend lines to match diagram
* receive brake line clips in the mail
* attach clips to existing holes on pedal plate and chassis according to diagram
* screw on brake line fittings; line/flare wrench required, SAE and Metric

===Brake Fluid===

* buy, locally, DOT3 brake fluid; CAUTIION: Brake fluid is one of the few seriously toxic fluids we deal with. Be careful, goggles and latex gloves are suggested.
* fill brake fluid resevoir
* bleed brakes; Requires brake bleeder kit or modified empty water bottle or 3/16th surgical tube.
* Verify brake pressure; Step on brake and verify rock-hard pedal before pedal is fully depressed. Have friends heave on the car and verify car slides before wheels rotate.

===Steering Chassis===

===Steering Rack===

* receive steering rack in the mail.
* receive steering rack mounts in the mail or make locally with CNC.
* bolt steering rack mounts to pedal plate; recieve grade 8, 3/8" bolts, washers, and lock nuts
* bolt steering rack to steering rack mounts; recieve grade 8, 3/8" bolts, washers, and lock nuts
* receive tie rod extendors in the mail or tap locally from hexagonal bar stock.; if tapping locally, need metric tap, I believe M14x1.5.
* receive tie rods in the mail.
* thread tie rods onto tie rod extendors.
* thread tie rod extendors onto steering rack.
* bolt tie rods to steering knuckles.
* verify can heave on front wheel by hand and one wheel does not move at all without the opposite wheel moving.

===Steering Column===

* receive steering column in the mail.
* receive interior module in mail or cut and weld locally; same tools required as making a chassis.
* set interior module in chassis, and bolt in; recieve grade 8, 3/8" bolts, washers, and lock nuts
* receive steering wheel in the mail.
* slide steering column onto steering rack, tighten pinch bolt; metric socket set required.
* attach steering column to interior module.
* Bolt steering wheel to steering rack; SAE socket set required
* verify steering wheel turns both wheels without wobbling.
* align wheels (professional alignment or local with speed square, plumb bob, and level).

===Body On===

===Body Top Mount Frame===

* receive body top mount frame in the mail
* receive button-head hex bolts in mail.
* bolt body top mount frame to car
* receive body by freight.
* set body onto body top mount frame.
* bolt body on to body top mount frame with button-hread hex bolts.
* push and shake body, verify does not flex, wobble, or make noise under force that would dent a fender on a new car.
* dust and polish car body.

==Build Steps for Volume Scenarios==

* Chassis Machining
** extrusions set on templates on aluminum router
** aluminum milling
** test milled aluminum on test fixture (welding jig)

* Chassis Weld
** seam weld along marked paths in welding jig

* Mold Making
** foam on foam router
** foam milling
** test foam on test fixture (CMM)
** send picture from CMM super-imposed over foam photo to customer
** visual inspection and scabbing in

* Composites Layup
** unroll prepreg sheets onto body,
** place core material on router
** test core material on test fixtures
** place core material in mold.
** unroll prepreg sheets over core material
** place thermocouples and vacuum ports in mold
** place vacuum sheet in mold
** place pleats as needed in vacuum sheet.
** test vacuum seal, troubleshoot.
** apply vacuuum

* Composites Debulking
** remove vacuum bag, tensile strength test flashing, take picture and send to customer
** remove from mold, grind off flashing. sand.

* Body Finishing
** place on CNC
** CNC drills body access holes and mount holes
** sand body
** wash body

* Vinyl Wrap
** print vinyl wrap
** unroll vinyl wrap
** apply, squeegee, heat, disperse bubbles of wrap.

* Suspension Corners
** assemble dampers
** adjust dampers
** assemble knuckles
** assemble A-arms to suspension plates with Heim joints
** assemble strut top mounts to plates with bolts
** attach steering kunckles to damper bodies
** attach steering knuckles and dampers to suspension plates
** assemble calipers
** attach rotors and calipers
** place all 4 suspension corners on test fixture

* Engine Module
** assemble engine on engine test fixture (engine cradle)
** attach transmission, longblock components
** attach air intake, exhaust header, fuel system
** test fuel system
** test air system
** test compression
** dyno and fuel consumption test on test jig,

* Electrical Module
** form electrical module box (router, or vacuum form, or composite)
** load PCB on router
** machine PCB
** set PCB on test fixture
** place PCB in electrical module box.
** solder in wiring connections
** pot in wiring connections
** connect wiring connections to RJ45 jacks
** place RJ45 jacks in knockouts on electrical module box
** connect electrical module box to test fixture

* Body Electrical
** insert lights and sensors into body
** attach Cat5e cable to body, connect to lights and sensors
** connect body electrical to test fixture
** see machining, mold, body electrical steps.

* Interior module
* dash panel
* pedal plate
* HVAC system
* stereo
* windsheild wiper and fluid
* door/hinge/clam/latches
* rolling chassis
* cargo spaces/liners/lighting
* wheel wells
* integrated vehicle test
* ABS
* VSC
* tire pressure monitoring
* MILs
* alignment check jig

[[Category:Wikispeed]]

Wikispeed SGT01

2012-06-12T03:59:05Z

Matt Maier: /* Suspension Module */

NOTE- this article is flagged for re-title to "SGT01", for super grant touring 01.

Team Wikispeed has open sourced their first car! They agree with OSE, and the open source movement, that everyone will benefit faster when there are fewer barriers to innovation and collaboration.

It is important to note, however, that the STG01 is not the GVCS car. It was designed to compete in the Progressive Automotive X-prize, not to be made out of the common modular pieces of the GVCS. But the principles/processes are largely the same, and many of the control/interface systems can be identical.

=Wikispeed STG01=

==CAD==

[[image:SGT01 2011 June 28th angle view.gif|thumb]]

The following CAD files are STEP 203's that were exported from the Alibre files Wikispeed uses.

The assembled vehicle (mostly).
* [[File:Wikispeed_SGT01_Assembled.stp]]

Chassis Module
* [[File:Wikispeed_SGT01_Chassis.stp]]
<gallery>
image:Wikispeed_SGT01_Chassis.jpeg
</gallery>

Bulkhead Plate
* Attaches to the front of the chassis
* Used to mount things like the brake cylinder
* [[File:Wikispeed_SGT01_Bulkhead_Plate.stp]]
<gallery>
image:Wikispeed_SGT01_Bulkhead_Plate.jpeg
</gallery>

Engine Module Frame
* [[File:Wikispeed_SGT01_Engine_Module_Frame.stp]]
<gallery>
image:Wikispeed_SGT01_Engine_Module_Frame.jpeg
</gallery>

Floor Plate
* Attaches to the bottom of the chassis
* [[File:Wikispeed_SGT01_Floor_Plate.stp]]
<gallery>
image:Wikispeed_SGT01_Floor_Plate.jpeg
</gallery>

Crush Structures
* Attaches to the front/rear of the chassis
* Serves as a sacrificial crumple zone in the event of a crash
* Used to mount things like headlights
* [[File:Wikispeed_SGT01_Front_Crush_Structure.stp]]
* [[File:Wikispeed_SGT01_Rear_Crush_Structure.stp]]
<gallery>
image:Wikispeed_SGT01_Front_Crush_Structure.jpeg
image:Wikispeed_SGT01_Rear_Crush_Structure.jpeg
</gallery>

Interior Module
* This is the interior module as an aluminum tube frame
* [[File:Wikispeed_SGT01_Interior_Module_Frame.stp]]
* This is the interior module as an aluminum bathtub
* [[File:Wikispeed_SGT01_Interior_Module.stp]]
<gallery>
image:Wikispeed_SGT01_Interior_Module_Frame.jpeg
image:Wikispeed_SGT01_Interior_Module.jpeg
</gallery>

The Assembled Suspension
* [[File:Wikispeed_SGT01_PassSide_Suspension_v3.stp]]
<gallery>
image:Wikispeed_SGT01_PassSide_Suspension_v3.jpeg
</gallery>

Suspension Components
* Tie Rod
* [[File:Wikispeed_SGT01_Suspension_Left_Tie_Rod.stp]]
* Lower Control Arm
* [[File:Wikispeed_SGT01_Suspension_Lower_Control_Arm.stp]]
* Hub pivot point
* [[File:Wikispeed_SGT01_Suspension_Lower_Hub_Pivot_v2.stp]]
* mount plate
* This is what holds the suspension together and attaches it to the chassis
* [[File:Wikispeed_SGT01_Suspension_Mount_Plate.stp]]
* strut mount
* [[File:Wikispeed_SGT01_Suspension_Strut_Top_Mount.stp]]
<gallery>
image:Wikispeed_SGT01_Suspension_Left_Tie_Rod.jpeg
image:Wikispeed_SGT01_Suspension_Lower_Control_Arm.jpeg
image:Wikispeed_SGT01_Suspension_Lower_Hub_Pivot_v2.jpeg
image:Wikispeed_SGT01_Suspension_Mount_Plate.jpeg
image:Wikispeed_SGT01_Suspension_Strut_Top_Mount.jpeg
image:IMG_9876.JPG
image:IMG_9871.JPG
image:IMG_9872.JPG
image:IMG_9867.JPG
image:IMG_9866.JPG
image:IMG_9873.JPG
</gallery>

Body Frame
* This frame mounts any aerodynamic body to the chassis
* [[File:Wiklspeed_SGT01_Body_Module_Mount_Frame.stp]]
<gallery>
image:Wikispeed_SGT01_Body_Module_Mount_Frame.jpeg
</gallery>

==Bill of Materials==

* Chassis ~$434
** 4"x4"x.125" extruded square tube 6061-T6
** brake lines, 28'
** floor 78"x48"

* Engine Module ~$8422 (from Honda Performance Development)
** GENERAL ASSY., CYLINDER BLOCK (DOT)
** GENERAL ASSY., CYLINDER HEAD
** WIRE HARNESS, ENGINE
** ALTERNATOR ASSY. (AHGA67) (MITSUBISHI)
** BRACKET, ALTERNATOR
** 4x4x.125" extruded square tube (140 feet?) 6061-T6
** camshaft, cam chain
** clutch - torque converter
** Catalytic Converter
** Injector Assy, Fuel
** Gasket Kit (engine, transmission, chain case)
** Intake Manifold
** Pump Assy, oil
** plug hole coil
** spool valve
** STARTER MOTOR ASSY(SM-71001)MITSUBA
** Throttle Body 1.8L
** ARM ASSY., ROCKER
** water hose (1.8l)
** water pump (1.8l)
** 5AT Transmission
** 5MT Transmission
** Radiator
** Radiator hose
** ECU 1.8L MT

* Engine Module Least Expensive ~$5232 (Honda Performance Development)
** L15A crate engine
** L15A 5MT
** L15A ECU 5MT
** L15A ignition
** L15A key
** L15A engine harness
** L15A dash harness
** Radiator
** Radiator Fan+shroud+motor
** Radiator hose

* Engine Module More Power ~$8815 (Honda Performance Development)
** Civic Type R crate engine
** Si 6MT
** Hondata ECU
** Civic Si ignition
** Civic Si key
** Civic Si engine harness
** Civic Si dash harness

* Engine Module Frame ~$169 (for 2 units)
** 1.25x1.25x.125" 6061-T6 tube (34.4 feet?)

* Suspension ~$4283 (for 4 units)
** Skunk2 Pro C
** 15x7 MOTEGI RACING SP10 HB
** 195/65R-15 Bridgestone Ecopia EP100
** .25" thick plate, 2'x2' 6061-T6
** strut top mount angle 6061-T6
** 3/8ths x24 grade 8 bolts
** 3/8ths x2 lock nuts
** 1" OD 3/8ths ID steel washers
* (Honda Performance Development)
** Front Knuckle
** Joint F. Ball Lower
** Bearing Assy, Front Hub
** Hub Assy, Front.
** Disk Fr Brake
** Caliper sub assembly, FR
** Pad Set, FR.
** knuckle bolts (BOLT, FLANGE (14X57)) (2)
** knuckle bolt nuts (NUT, SELF-LOCK (14MM)) (2)
** strut top mount nuts (NUT, FLANGE (10MM)) (3)

* Pedal Plate ~$243
** steering column (summit racing)
* (Willwood)
** steering rack
** CMB-14-0010 master cylinder and pedal combo
** ABS block and proportioning valve: WIL-260-11179
** APS229 - Standard Motor Accelerator Pedal Sensors

* Front Crush Zone ~$22
** 6x6x.125" 6061-T6 square tube (9.1 feet?)

* Rear Crush Zone ~$19
** 6x6x.125" 6061-T6 square tube (7.75 feet?)

* Side Crush Zone/Trunk ~$169 (for 2 units)
** 1.25x1.25x.125" 6061-T6 tube (34.4 feet?)

* Body/Aeroshell ~$1107
** polycarbonate (US plastics) (4'x8' x 1/8" sheet)
** nida core honeycomb (NW composits) (4'x8' x 1/2" sheet)
** rivets
* (US Composits)
** 5.7oz Carbon Plain weeve (50" x 18 yards)
** epoxy (54 gal)
** hardner (18 gal)
** 10oz e-glass mat (50" x 18 yards)
** e-glass biaxial mat 1208 (50" x 18 yards)

* Body Top Mount Frame ~$169 (for 2 units)
** 1.25x1.25x.125" 6061-T6 square tube (12.5 feet?)

* Interior ~$823
** carpet 40"x6'
** Autoloc 3 point belt (2)
* (US Composits)
** 5.7oz carbon plain weeve (6)
** epoxy
** hardner
** 10oz e-glass mat (6)
** e-glass biaxial mat 1208 (6)
* (Summit Racing)
** GRT-687 GRANT RACING STEERING WHEEL
** SUM-800600 DIGITAL 6 GAUGE PANEL
** poly seat black 2100 series & cover combo (2)
** DUAL LOCK SLIDING SEAT BRCK PR (2)
** SUM-G1122 COVER & BRACKET KIT SINGLE
** CIP-19100 REPL MIRROR PAIR
** SUM-G2111 seat cover for G2100 seat (2)

* Wikispeedlet ~$271
** 5-1577-4 3.93" STROKE 107 LB. 12 VDC LINEAR A (Surplus Center)
** 5-1577-B LINEAR ACTUATOR MOUNTING BRCKT (Surplus Center)
** Arduino Uno (Maker Shed)
** 12v to 5v converter
** Box, 12"x12"x4".
** PEDAL ASSY., ACCELERATOR (Summit Racing)

* MT Shift Control ~$233
** 5-1577-4 3.93" STROKE 107 LB. 12 VDC LINEAR A
** 5-1577-B LINEAR ACTUATOR MOUNTING BRCKT
** Arduino Uno
** 12v to 5v converter
** Box, 12"x12"x4".

==Chassis==

The Wikispeed car(s) is always evolving, so it's best to start with a piece that hasn't significantly changed in a while. The basic chassis is nothing more than 4" square aluminum extrusion welded into a series of boxes. However, it has a 5-star crash equivalency rating. It is only around $550 in parts and those parts are commodities, so they can be overnighted pretty much anywhere in the world. All you need to build the chassis is an average sized garage, a saw to cut the aluminum, and a welder to fasten it together.

Illustrations are on the way.

BOM
* 4" x 1/8" thick square tube
** 120" long (x4)
** 40" long (x4)
** 12" long (x6)
* Yeah, that's it. That's all the frame is made out of :-)

Project Steps
* Cut aluminum tube to specified lengths
* The only location that needs to be measured
** The center vertical tube is 36" from the inside of the vertical tubes on the open end of the chassis and 72" from the inside of the vertical tubes on the closed end
** Other than that, everything lines up on obvious edges

===From Joe's Notebook===

For the aluminum, we use Coast aluminum over here, and order 500 lbs at a time in stock lengths. This lets us get a discount, and by always ordering whatever length they stock we avoid "cut fee's". For the build, it is ideal to have 3' on each side of parts we are working on. For the chassis, it's 4'x10, so 10'x16' is ideal. The total car, with body, is larger at 6.5'x14', so 12.5'x20' is ideal. It can be worked with far less, however, and I think the ultimate flow of work, when it is optimized, will be to manufacture these inside a shipping container "factory" that can be shipped to wherever the local demand might be.

The jig plates [specifications on the way] are a pre-requite for building the chassis...After each weld, the surface is grounded down (4" electric grinder, or, a coarse file and some hand work) so that the jig plate can be bolted back on flush. At the end, the jig plates are actually other modules- the roll bar mounts and the suspension plates, so they simply have the rest of their components bolted on and now there is a rolling chassis.

Using the jig plates and a 3/8ths centering punch, holes can be drilled to attach the frame to the jig with bolts, then the frame is tack welded, then the jig plates are removed and replaced one corner at a time while the frame is seem welded with the other jigs holding the chassis square as it is heated and cooled during the welding.

The current configuration requires 18.33 KW to bring its 1404 weight plus a 150 lb driver (EPA standard) through the UDDS city test, and 15.11 for the HWFET highway test. However, to meet the X Prize minimums (no-longer required but researched by the X Prize as acceptable minimums for mainstream market interest) our vehicles requires 31.1kw to go from 40mph to 65mph in less than 9 seconds. This is approximately 41.7hp. 50hp or larger gives us a safe target to determine in the drive-train meets our minimums. Please note the current 140hp engine module weighs about 700lbs. That includes fuel, emissions system, cooling system, axles, transmission, engine, engine electronics, data logging, battery, coolant, all fluids, 4 gallons of gas, aluminum engine module cradle.

==Build Steps for Small Volume Scenarios==

===Rolling Chassis===

===Chassis===

* receive in mail or cut and weld on location. http://www.youtube.com/watch?v=YvN8ZF1-ogY&context=C4d5a23fADvjVQa1PpcFNIheMStKChcQuO9z0Bcs9fLnn3W5EWwXM=
* cut and weld on location requires bandsaw set to cut square, jig plates (can be mailed or CNC'd locally), speed square and accurate 48" tape measure with 1/16th" or smaller tick marks.
* If made on site, chassis must then be drilled, requires centering punch, hammer, centering 3/8ths drill bit and drill (drill press or coal drill preferred).

===Suspension Module===

* 12 strut top nuts
* 4 Skunk2 Pro C adjustable struts
* 4 brake calipers/pads/bolts
* 8 19mm bolts for knuckles on strut
* 4 lower knuckle ball joints/fasteners/lock nuts
* 32 grade 8 bolts/lock nuts to attach plate to chassis
* 20 lug nuts
* receive in mail or CNC on location.
* Assemble
* compare to photos for test.
* bolt on to car
* recieve grade 8, 3/8" bolts, washers, and lock nuts
* 9/16ths wrench and socket with ratchet required
* compare to photos for test.
* it should be possible to swap out a cheaper strut however, the details are not straight forward. The main problem is that struts are usually pretty tall. The adjustable ones can be lowered, reducing their height by as much as 6" (more or less).

===Wheels & Tires===

* receive wheels with tires and lungnuts in mail (tirerack)
* jack up chassis; set up car jack; put wood block on car jack to avoid scratching frame.
* bolt on wheels; Lug wrench required

===Braking Chassis===

===Pedal Plate===

* receive pedal plate in mail or CNC on location.
* bolt pedal plate onto chassis; recieve grade 8, 3/8" bolts, washers, and lock nuts
* receive brake pedal in mail (willwood)
* receive brake master cylinder in mail (willwood)
* receive accelerator pedal in mail.
* bolt pedals and master cylinder to pre-drilled holes on pedal plate; recieve grade 8, 1/4" bolts, washers, and lock nuts

===Brake Lines===

* receive brake lines in the mail, pre-flared or flare on location; if flaring on location, requires bubble flare tool, metric AND SAE brake line fittings.
* bend lines to match diagram
* receive brake line clips in the mail
* attach clips to existing holes on pedal plate and chassis according to diagram
* screw on brake line fittings; line/flare wrench required, SAE and Metric

===Brake Fluid===

* buy, locally, DOT3 brake fluid; CAUTIION: Brake fluid is one of the few seriously toxic fluids we deal with. Be careful, goggles and latex gloves are suggested.
* fill brake fluid resevoir
* bleed brakes; Requires brake bleeder kit or modified empty water bottle or 3/16th surgical tube.
* Verify brake pressure; Step on brake and verify rock-hard pedal before pedal is fully depressed. Have friends heave on the car and verify car slides before wheels rotate.

===Steering Chassis===

===Steering Rack===

* receive steering rack in the mail.
* receive steering rack mounts in the mail or make locally with CNC.
* bolt steering rack mounts to pedal plate; recieve grade 8, 3/8" bolts, washers, and lock nuts
* bolt steering rack to steering rack mounts; recieve grade 8, 3/8" bolts, washers, and lock nuts
* receive tie rod extendors in the mail or tap locally from hexagonal bar stock.; if tapping locally, need metric tap, I believe M14x1.5.
* receive tie rods in the mail.
* thread tie rods onto tie rod extendors.
* thread tie rod extendors onto steering rack.
* bolt tie rods to steering knuckles.
* verify can heave on front wheel by hand and one wheel does not move at all without the opposite wheel moving.

===Steering Column===

* receive steering column in the mail.
* receive interior module in mail or cut and weld locally; same tools required as making a chassis.
* set interior module in chassis, and bolt in; recieve grade 8, 3/8" bolts, washers, and lock nuts
* receive steering wheel in the mail.
* slide steering column onto steering rack, tighten pinch bolt; metric socket set required.
* attach steering column to interior module.
* Bolt steering wheel to steering rack; SAE socket set required
* verify steering wheel turns both wheels without wobbling.
* align wheels (professional alignment or local with speed square, plumb bob, and level).

===Body On===

===Body Top Mount Frame===

* receive body top mount frame in the mail
* receive button-head hex bolts in mail.
* bolt body top mount frame to car
* receive body by freight.
* set body onto body top mount frame.
* bolt body on to body top mount frame with button-hread hex bolts.
* push and shake body, verify does not flex, wobble, or make noise under force that would dent a fender on a new car.
* dust and polish car body.

==Build Steps for Volume Scenarios==

* Chassis Machining
** extrusions set on templates on aluminum router
** aluminum milling
** test milled aluminum on test fixture (welding jig)

* Chassis Weld
** seam weld along marked paths in welding jig

* Mold Making
** foam on foam router
** foam milling
** test foam on test fixture (CMM)
** send picture from CMM super-imposed over foam photo to customer
** visual inspection and scabbing in

* Composites Layup
** unroll prepreg sheets onto body,
** place core material on router
** test core material on test fixtures
** place core material in mold.
** unroll prepreg sheets over core material
** place thermocouples and vacuum ports in mold
** place vacuum sheet in mold
** place pleats as needed in vacuum sheet.
** test vacuum seal, troubleshoot.
** apply vacuuum

* Composites Debulking
** remove vacuum bag, tensile strength test flashing, take picture and send to customer
** remove from mold, grind off flashing. sand.

* Body Finishing
** place on CNC
** CNC drills body access holes and mount holes
** sand body
** wash body

* Vinyl Wrap
** print vinyl wrap
** unroll vinyl wrap
** apply, squeegee, heat, disperse bubbles of wrap.

* Suspension Corners
** assemble dampers
** adjust dampers
** assemble knuckles
** assemble A-arms to suspension plates with Heim joints
** assemble strut top mounts to plates with bolts
** attach steering kunckles to damper bodies
** attach steering knuckles and dampers to suspension plates
** assemble calipers
** attach rotors and calipers
** place all 4 suspension corners on test fixture

* Engine Module
** assemble engine on engine test fixture (engine cradle)
** attach transmission, longblock components
** attach air intake, exhaust header, fuel system
** test fuel system
** test air system
** test compression
** dyno and fuel consumption test on test jig,

* Electrical Module
** form electrical module box (router, or vacuum form, or composite)
** load PCB on router
** machine PCB
** set PCB on test fixture
** place PCB in electrical module box.
** solder in wiring connections
** pot in wiring connections
** connect wiring connections to RJ45 jacks
** place RJ45 jacks in knockouts on electrical module box
** connect electrical module box to test fixture

* Body Electrical
** insert lights and sensors into body
** attach Cat5e cable to body, connect to lights and sensors
** connect body electrical to test fixture
** see machining, mold, body electrical steps.

* Interior module
* dash panel
* pedal plate
* HVAC system
* stereo
* windsheild wiper and fluid
* door/hinge/clam/latches
* rolling chassis
* cargo spaces/liners/lighting
* wheel wells
* integrated vehicle test
* ABS
* VSC
* tire pressure monitoring
* MILs
* alignment check jig

[[Category:Wikispeed]]

Wikispeed SGT01

2012-06-12T03:54:42Z

Matt Maier: /* CAD */

NOTE- this article is flagged for re-title to "SGT01", for super grant touring 01.

Team Wikispeed has open sourced their first car! They agree with OSE, and the open source movement, that everyone will benefit faster when there are fewer barriers to innovation and collaboration.

It is important to note, however, that the STG01 is not the GVCS car. It was designed to compete in the Progressive Automotive X-prize, not to be made out of the common modular pieces of the GVCS. But the principles/processes are largely the same, and many of the control/interface systems can be identical.

=Wikispeed STG01=

==CAD==

[[image:SGT01 2011 June 28th angle view.gif|thumb]]

The following CAD files are STEP 203's that were exported from the Alibre files Wikispeed uses.

The assembled vehicle (mostly).
* [[File:Wikispeed_SGT01_Assembled.stp]]

Chassis Module
* [[File:Wikispeed_SGT01_Chassis.stp]]
<gallery>
image:Wikispeed_SGT01_Chassis.jpeg
</gallery>

Bulkhead Plate
* Attaches to the front of the chassis
* Used to mount things like the brake cylinder
* [[File:Wikispeed_SGT01_Bulkhead_Plate.stp]]
<gallery>
image:Wikispeed_SGT01_Bulkhead_Plate.jpeg
</gallery>

Engine Module Frame
* [[File:Wikispeed_SGT01_Engine_Module_Frame.stp]]
<gallery>
image:Wikispeed_SGT01_Engine_Module_Frame.jpeg
</gallery>

Floor Plate
* Attaches to the bottom of the chassis
* [[File:Wikispeed_SGT01_Floor_Plate.stp]]
<gallery>
image:Wikispeed_SGT01_Floor_Plate.jpeg
</gallery>

Crush Structures
* Attaches to the front/rear of the chassis
* Serves as a sacrificial crumple zone in the event of a crash
* Used to mount things like headlights
* [[File:Wikispeed_SGT01_Front_Crush_Structure.stp]]
* [[File:Wikispeed_SGT01_Rear_Crush_Structure.stp]]
<gallery>
image:Wikispeed_SGT01_Front_Crush_Structure.jpeg
image:Wikispeed_SGT01_Rear_Crush_Structure.jpeg
</gallery>

Interior Module
* This is the interior module as an aluminum tube frame
* [[File:Wikispeed_SGT01_Interior_Module_Frame.stp]]
* This is the interior module as an aluminum bathtub
* [[File:Wikispeed_SGT01_Interior_Module.stp]]
<gallery>
image:Wikispeed_SGT01_Interior_Module_Frame.jpeg
image:Wikispeed_SGT01_Interior_Module.jpeg
</gallery>

The Assembled Suspension
* [[File:Wikispeed_SGT01_PassSide_Suspension_v3.stp]]
<gallery>
image:Wikispeed_SGT01_PassSide_Suspension_v3.jpeg
</gallery>

Suspension Components
* Tie Rod
* [[File:Wikispeed_SGT01_Suspension_Left_Tie_Rod.stp]]
* Lower Control Arm
* [[File:Wikispeed_SGT01_Suspension_Lower_Control_Arm.stp]]
* Hub pivot point
* [[File:Wikispeed_SGT01_Suspension_Lower_Hub_Pivot_v2.stp]]
* mount plate
* This is what holds the suspension together and attaches it to the chassis
* [[File:Wikispeed_SGT01_Suspension_Mount_Plate.stp]]
* strut mount
* [[File:Wikispeed_SGT01_Suspension_Strut_Top_Mount.stp]]
<gallery>
image:Wikispeed_SGT01_Suspension_Left_Tie_Rod.jpeg
image:Wikispeed_SGT01_Suspension_Lower_Control_Arm.jpeg
image:Wikispeed_SGT01_Suspension_Lower_Hub_Pivot_v2.jpeg
image:Wikispeed_SGT01_Suspension_Mount_Plate.jpeg
image:Wikispeed_SGT01_Suspension_Strut_Top_Mount.jpeg
image:IMG_9876.JPG
image:IMG_9871.JPG
image:IMG_9872.JPG
image:IMG_9867.JPG
image:IMG_9866.JPG
image:IMG_9873.JPG
</gallery>

Body Frame
* This frame mounts any aerodynamic body to the chassis
* [[File:Wiklspeed_SGT01_Body_Module_Mount_Frame.stp]]
<gallery>
image:Wikispeed_SGT01_Body_Module_Mount_Frame.jpeg
</gallery>

==Bill of Materials==

* Chassis ~$434
** 4"x4"x.125" extruded square tube 6061-T6
** brake lines, 28'
** floor 78"x48"

* Engine Module ~$8422 (from Honda Performance Development)
** GENERAL ASSY., CYLINDER BLOCK (DOT)
** GENERAL ASSY., CYLINDER HEAD
** WIRE HARNESS, ENGINE
** ALTERNATOR ASSY. (AHGA67) (MITSUBISHI)
** BRACKET, ALTERNATOR
** 4x4x.125" extruded square tube (140 feet?) 6061-T6
** camshaft, cam chain
** clutch - torque converter
** Catalytic Converter
** Injector Assy, Fuel
** Gasket Kit (engine, transmission, chain case)
** Intake Manifold
** Pump Assy, oil
** plug hole coil
** spool valve
** STARTER MOTOR ASSY(SM-71001)MITSUBA
** Throttle Body 1.8L
** ARM ASSY., ROCKER
** water hose (1.8l)
** water pump (1.8l)
** 5AT Transmission
** 5MT Transmission
** Radiator
** Radiator hose
** ECU 1.8L MT

* Engine Module Least Expensive ~$5232 (Honda Performance Development)
** L15A crate engine
** L15A 5MT
** L15A ECU 5MT
** L15A ignition
** L15A key
** L15A engine harness
** L15A dash harness
** Radiator
** Radiator Fan+shroud+motor
** Radiator hose

* Engine Module More Power ~$8815 (Honda Performance Development)
** Civic Type R crate engine
** Si 6MT
** Hondata ECU
** Civic Si ignition
** Civic Si key
** Civic Si engine harness
** Civic Si dash harness

* Engine Module Frame ~$169 (for 2 units)
** 1.25x1.25x.125" 6061-T6 tube (34.4 feet?)

* Suspension ~$4283 (for 4 units)
** Skunk2 Pro C
** 15x7 MOTEGI RACING SP10 HB
** 195/65R-15 Bridgestone Ecopia EP100
** .25" thick plate, 2'x2' 6061-T6
** strut top mount angle 6061-T6
** 3/8ths x24 grade 8 bolts
** 3/8ths x2 lock nuts
** 1" OD 3/8ths ID steel washers
* (Honda Performance Development)
** Front Knuckle
** Joint F. Ball Lower
** Bearing Assy, Front Hub
** Hub Assy, Front.
** Disk Fr Brake
** Caliper sub assembly, FR
** Pad Set, FR.
** knuckle bolts (BOLT, FLANGE (14X57)) (2)
** knuckle bolt nuts (NUT, SELF-LOCK (14MM)) (2)
** strut top mount nuts (NUT, FLANGE (10MM)) (3)

* Pedal Plate ~$243
** steering column (summit racing)
* (Willwood)
** steering rack
** CMB-14-0010 master cylinder and pedal combo
** ABS block and proportioning valve: WIL-260-11179
** APS229 - Standard Motor Accelerator Pedal Sensors

* Front Crush Zone ~$22
** 6x6x.125" 6061-T6 square tube (9.1 feet?)

* Rear Crush Zone ~$19
** 6x6x.125" 6061-T6 square tube (7.75 feet?)

* Side Crush Zone/Trunk ~$169 (for 2 units)
** 1.25x1.25x.125" 6061-T6 tube (34.4 feet?)

* Body/Aeroshell ~$1107
** polycarbonate (US plastics) (4'x8' x 1/8" sheet)
** nida core honeycomb (NW composits) (4'x8' x 1/2" sheet)
** rivets
* (US Composits)
** 5.7oz Carbon Plain weeve (50" x 18 yards)
** epoxy (54 gal)
** hardner (18 gal)
** 10oz e-glass mat (50" x 18 yards)
** e-glass biaxial mat 1208 (50" x 18 yards)

* Body Top Mount Frame ~$169 (for 2 units)
** 1.25x1.25x.125" 6061-T6 square tube (12.5 feet?)

* Interior ~$823
** carpet 40"x6'
** Autoloc 3 point belt (2)
* (US Composits)
** 5.7oz carbon plain weeve (6)
** epoxy
** hardner
** 10oz e-glass mat (6)
** e-glass biaxial mat 1208 (6)
* (Summit Racing)
** GRT-687 GRANT RACING STEERING WHEEL
** SUM-800600 DIGITAL 6 GAUGE PANEL
** poly seat black 2100 series & cover combo (2)
** DUAL LOCK SLIDING SEAT BRCK PR (2)
** SUM-G1122 COVER & BRACKET KIT SINGLE
** CIP-19100 REPL MIRROR PAIR
** SUM-G2111 seat cover for G2100 seat (2)

* Wikispeedlet ~$271
** 5-1577-4 3.93" STROKE 107 LB. 12 VDC LINEAR A (Surplus Center)
** 5-1577-B LINEAR ACTUATOR MOUNTING BRCKT (Surplus Center)
** Arduino Uno (Maker Shed)
** 12v to 5v converter
** Box, 12"x12"x4".
** PEDAL ASSY., ACCELERATOR (Summit Racing)

* MT Shift Control ~$233
** 5-1577-4 3.93" STROKE 107 LB. 12 VDC LINEAR A
** 5-1577-B LINEAR ACTUATOR MOUNTING BRCKT
** Arduino Uno
** 12v to 5v converter
** Box, 12"x12"x4".

==Chassis==

The Wikispeed car(s) is always evolving, so it's best to start with a piece that hasn't significantly changed in a while. The basic chassis is nothing more than 4" square aluminum extrusion welded into a series of boxes. However, it has a 5-star crash equivalency rating. It is only around $550 in parts and those parts are commodities, so they can be overnighted pretty much anywhere in the world. All you need to build the chassis is an average sized garage, a saw to cut the aluminum, and a welder to fasten it together.

Illustrations are on the way.

BOM
* 4" x 1/8" thick square tube
** 120" long (x4)
** 40" long (x4)
** 12" long (x6)
* Yeah, that's it. That's all the frame is made out of :-)

Project Steps
* Cut aluminum tube to specified lengths
* The only location that needs to be measured
** The center vertical tube is 36" from the inside of the vertical tubes on the open end of the chassis and 72" from the inside of the vertical tubes on the closed end
** Other than that, everything lines up on obvious edges

===From Joe's Notebook===

For the aluminum, we use Coast aluminum over here, and order 500 lbs at a time in stock lengths. This lets us get a discount, and by always ordering whatever length they stock we avoid "cut fee's". For the build, it is ideal to have 3' on each side of parts we are working on. For the chassis, it's 4'x10, so 10'x16' is ideal. The total car, with body, is larger at 6.5'x14', so 12.5'x20' is ideal. It can be worked with far less, however, and I think the ultimate flow of work, when it is optimized, will be to manufacture these inside a shipping container "factory" that can be shipped to wherever the local demand might be.

The jig plates [specifications on the way] are a pre-requite for building the chassis...After each weld, the surface is grounded down (4" electric grinder, or, a coarse file and some hand work) so that the jig plate can be bolted back on flush. At the end, the jig plates are actually other modules- the roll bar mounts and the suspension plates, so they simply have the rest of their components bolted on and now there is a rolling chassis.

Using the jig plates and a 3/8ths centering punch, holes can be drilled to attach the frame to the jig with bolts, then the frame is tack welded, then the jig plates are removed and replaced one corner at a time while the frame is seem welded with the other jigs holding the chassis square as it is heated and cooled during the welding.

The current configuration requires 18.33 KW to bring its 1404 weight plus a 150 lb driver (EPA standard) through the UDDS city test, and 15.11 for the HWFET highway test. However, to meet the X Prize minimums (no-longer required but researched by the X Prize as acceptable minimums for mainstream market interest) our vehicles requires 31.1kw to go from 40mph to 65mph in less than 9 seconds. This is approximately 41.7hp. 50hp or larger gives us a safe target to determine in the drive-train meets our minimums. Please note the current 140hp engine module weighs about 700lbs. That includes fuel, emissions system, cooling system, axles, transmission, engine, engine electronics, data logging, battery, coolant, all fluids, 4 gallons of gas, aluminum engine module cradle.

==Build Steps for Small Volume Scenarios==

===Rolling Chassis===

===Chassis===

* receive in mail or cut and weld on location. http://www.youtube.com/watch?v=YvN8ZF1-ogY&context=C4d5a23fADvjVQa1PpcFNIheMStKChcQuO9z0Bcs9fLnn3W5EWwXM=
* cut and weld on location requires bandsaw set to cut square, jig plates (can be mailed or CNC'd locally), speed square and accurate 48" tape measure with 1/16th" or smaller tick marks.
* If made on site, chassis must then be drilled, requires centering punch, hammer, centering 3/8ths drill bit and drill (drill press or coal drill preferred).

===Suspension Module===

* receive in mail or CNC on location.
* Assemble
* compare to photos for test.
* bolt on to car
* recieve grade 8, 3/8" bolts, washers, and lock nuts
* 9/16ths wrench and socket with ratchet required
* compare to photos for test.

===Wheels & Tires===

* receive wheels with tires and lungnuts in mail (tirerack)
* jack up chassis; set up car jack; put wood block on car jack to avoid scratching frame.
* bolt on wheels; Lug wrench required

===Braking Chassis===

===Pedal Plate===

* receive pedal plate in mail or CNC on location.
* bolt pedal plate onto chassis; recieve grade 8, 3/8" bolts, washers, and lock nuts
* receive brake pedal in mail (willwood)
* receive brake master cylinder in mail (willwood)
* receive accelerator pedal in mail.
* bolt pedals and master cylinder to pre-drilled holes on pedal plate; recieve grade 8, 1/4" bolts, washers, and lock nuts

===Brake Lines===

* receive brake lines in the mail, pre-flared or flare on location; if flaring on location, requires bubble flare tool, metric AND SAE brake line fittings.
* bend lines to match diagram
* receive brake line clips in the mail
* attach clips to existing holes on pedal plate and chassis according to diagram
* screw on brake line fittings; line/flare wrench required, SAE and Metric

===Brake Fluid===

* buy, locally, DOT3 brake fluid; CAUTIION: Brake fluid is one of the few seriously toxic fluids we deal with. Be careful, goggles and latex gloves are suggested.
* fill brake fluid resevoir
* bleed brakes; Requires brake bleeder kit or modified empty water bottle or 3/16th surgical tube.
* Verify brake pressure; Step on brake and verify rock-hard pedal before pedal is fully depressed. Have friends heave on the car and verify car slides before wheels rotate.

===Steering Chassis===

===Steering Rack===

* receive steering rack in the mail.
* receive steering rack mounts in the mail or make locally with CNC.
* bolt steering rack mounts to pedal plate; recieve grade 8, 3/8" bolts, washers, and lock nuts
* bolt steering rack to steering rack mounts; recieve grade 8, 3/8" bolts, washers, and lock nuts
* receive tie rod extendors in the mail or tap locally from hexagonal bar stock.; if tapping locally, need metric tap, I believe M14x1.5.
* receive tie rods in the mail.
* thread tie rods onto tie rod extendors.
* thread tie rod extendors onto steering rack.
* bolt tie rods to steering knuckles.
* verify can heave on front wheel by hand and one wheel does not move at all without the opposite wheel moving.

===Steering Column===

* receive steering column in the mail.
* receive interior module in mail or cut and weld locally; same tools required as making a chassis.
* set interior module in chassis, and bolt in; recieve grade 8, 3/8" bolts, washers, and lock nuts
* receive steering wheel in the mail.
* slide steering column onto steering rack, tighten pinch bolt; metric socket set required.
* attach steering column to interior module.
* Bolt steering wheel to steering rack; SAE socket set required
* verify steering wheel turns both wheels without wobbling.
* align wheels (professional alignment or local with speed square, plumb bob, and level).

===Body On===

===Body Top Mount Frame===

* receive body top mount frame in the mail
* receive button-head hex bolts in mail.
* bolt body top mount frame to car
* receive body by freight.
* set body onto body top mount frame.
* bolt body on to body top mount frame with button-hread hex bolts.
* push and shake body, verify does not flex, wobble, or make noise under force that would dent a fender on a new car.
* dust and polish car body.

==Build Steps for Volume Scenarios==

* Chassis Machining
** extrusions set on templates on aluminum router
** aluminum milling
** test milled aluminum on test fixture (welding jig)

* Chassis Weld
** seam weld along marked paths in welding jig

* Mold Making
** foam on foam router
** foam milling
** test foam on test fixture (CMM)
** send picture from CMM super-imposed over foam photo to customer
** visual inspection and scabbing in

* Composites Layup
** unroll prepreg sheets onto body,
** place core material on router
** test core material on test fixtures
** place core material in mold.
** unroll prepreg sheets over core material
** place thermocouples and vacuum ports in mold
** place vacuum sheet in mold
** place pleats as needed in vacuum sheet.
** test vacuum seal, troubleshoot.
** apply vacuuum

* Composites Debulking
** remove vacuum bag, tensile strength test flashing, take picture and send to customer
** remove from mold, grind off flashing. sand.

* Body Finishing
** place on CNC
** CNC drills body access holes and mount holes
** sand body
** wash body

* Vinyl Wrap
** print vinyl wrap
** unroll vinyl wrap
** apply, squeegee, heat, disperse bubbles of wrap.

* Suspension Corners
** assemble dampers
** adjust dampers
** assemble knuckles
** assemble A-arms to suspension plates with Heim joints
** assemble strut top mounts to plates with bolts
** attach steering kunckles to damper bodies
** attach steering knuckles and dampers to suspension plates
** assemble calipers
** attach rotors and calipers
** place all 4 suspension corners on test fixture

* Engine Module
** assemble engine on engine test fixture (engine cradle)
** attach transmission, longblock components
** attach air intake, exhaust header, fuel system
** test fuel system
** test air system
** test compression
** dyno and fuel consumption test on test jig,

* Electrical Module
** form electrical module box (router, or vacuum form, or composite)
** load PCB on router
** machine PCB
** set PCB on test fixture
** place PCB in electrical module box.
** solder in wiring connections
** pot in wiring connections
** connect wiring connections to RJ45 jacks
** place RJ45 jacks in knockouts on electrical module box
** connect electrical module box to test fixture

* Body Electrical
** insert lights and sensors into body
** attach Cat5e cable to body, connect to lights and sensors
** connect body electrical to test fixture
** see machining, mold, body electrical steps.

* Interior module
* dash panel
* pedal plate
* HVAC system
* stereo
* windsheild wiper and fluid
* door/hinge/clam/latches
* rolling chassis
* cargo spaces/liners/lighting
* wheel wells
* integrated vehicle test
* ABS
* VSC
* tire pressure monitoring
* MILs
* alignment check jig

[[Category:Wikispeed]]

File:IMG 9873.JPG

2012-06-12T03:54:28Z

Matt Maier:

File:IMG 9866.JPG

2012-06-12T03:54:04Z

Matt Maier:

File:IMG 9867.JPG

2012-06-12T03:53:45Z

Matt Maier:

File:IMG 9872.JPG

2012-06-12T03:53:25Z

Matt Maier:

File:IMG 9871.JPG

2012-06-12T03:52:57Z

Matt Maier:

File:IMG 9876.JPG

2012-06-12T03:52:23Z

Matt Maier:

Wikispeed SGT01

2012-04-10T03:24:38Z

Matt Maier: /* From Joe's Notebook */

NOTE- this article is flagged for re-title to "SGT01", for super grant touring 01.

Team Wikispeed has open sourced their first car! They agree with OSE, and the open source movement, that everyone will benefit faster when there are fewer barriers to innovation and collaboration.

It is important to note, however, that the STG01 is not the GVCS car. It was designed to compete in the Progressive Automotive X-prize, not to be made out of the common modular pieces of the GVCS. But the principles/processes are largely the same, and many of the control/interface systems can be identical.

=Wikispeed STG01=

==CAD==

[[image:SGT01 2011 June 28th angle view.gif|thumb]]

The following CAD files are STEP 203's that were exported from the Alibre files Wikispeed uses.

The assembled vehicle (mostly).
* [[File:Wikispeed_SGT01_Assembled.stp]]

Chassis Module
* [[File:Wikispeed_SGT01_Chassis.stp]]
<gallery>
image:Wikispeed_SGT01_Chassis.jpeg
</gallery>

Bulkhead Plate
* Attaches to the front of the chassis
* Used to mount things like the brake cylinder
* [[File:Wikispeed_SGT01_Bulkhead_Plate.stp]]
<gallery>
image:Wikispeed_SGT01_Bulkhead_Plate.jpeg
</gallery>

Engine Module Frame
* [[File:Wikispeed_SGT01_Engine_Module_Frame.stp]]
<gallery>
image:Wikispeed_SGT01_Engine_Module_Frame.jpeg
</gallery>

Floor Plate
* Attaches to the bottom of the chassis
* [[File:Wikispeed_SGT01_Floor_Plate.stp]]
<gallery>
image:Wikispeed_SGT01_Floor_Plate.jpeg
</gallery>

Crush Structures
* Attaches to the front/rear of the chassis
* Serves as a sacrificial crumple zone in the event of a crash
* Used to mount things like headlights
* [[File:Wikispeed_SGT01_Front_Crush_Structure.stp]]
* [[File:Wikispeed_SGT01_Rear_Crush_Structure.stp]]
<gallery>
image:Wikispeed_SGT01_Front_Crush_Structure.jpeg
image:Wikispeed_SGT01_Rear_Crush_Structure.jpeg
</gallery>

Interior Module
* This is the interior module as an aluminum tube frame
* [[File:Wikispeed_SGT01_Interior_Module_Frame.stp]]
* This is the interior module as an aluminum bathtub
* [[File:Wikispeed_SGT01_Interior_Module.stp]]
<gallery>
image:Wikispeed_SGT01_Interior_Module_Frame.jpeg
image:Wikispeed_SGT01_Interior_Module.jpeg
</gallery>

The Assembled Suspension
* [[File:Wikispeed_SGT01_PassSide_Suspension_v3.stp]]
<gallery>
image:Wikispeed_SGT01_PassSide_Suspension_v3.jpeg
</gallery>

Suspension Components
* Tie Rod
* [[File:Wikispeed_SGT01_Suspension_Left_Tie_Rod.stp]]
* Lower Control Arm
* [[File:Wikispeed_SGT01_Suspension_Lower_Control_Arm.stp]]
* Hub pivot point
* [[File:Wikispeed_SGT01_Suspension_Lower_Hub_Pivot_v2.stp]]
* mount plate
* This is what holds the suspension together and attaches it to the chassis
* [[File:Wikispeed_SGT01_Suspension_Mount_Plate.stp]]
* strut mount
* [[File:Wikispeed_SGT01_Suspension_Strut_Top_Mount.stp]]
<gallery>
image:Wikispeed_SGT01_Suspension_Left_Tie_Rod.jpeg
image:Wikispeed_SGT01_Suspension_Lower_Control_Arm.jpeg
image:Wikispeed_SGT01_Suspension_Lower_Hub_Pivot_v2.jpeg
image:Wikispeed_SGT01_Suspension_Mount_Plate.jpeg
image:Wikispeed_SGT01_Suspension_Strut_Top_Mount.jpeg
</gallery>

Body Frame
* This frame mounts any aerodynamic body to the chassis
* [[File:Wiklspeed_SGT01_Body_Module_Mount_Frame.stp]]
<gallery>
image:Wikispeed_SGT01_Body_Module_Mount_Frame.jpeg
</gallery>

==Bill of Materials==

* Chassis ~$434
** 4"x4"x.125" extruded square tube 6061-T6
** brake lines, 28'
** floor 78"x48"

* Engine Module ~$8422 (from Honda Performance Development)
** GENERAL ASSY., CYLINDER BLOCK (DOT)
** GENERAL ASSY., CYLINDER HEAD
** WIRE HARNESS, ENGINE
** ALTERNATOR ASSY. (AHGA67) (MITSUBISHI)
** BRACKET, ALTERNATOR
** 4x4x.125" extruded square tube (140 feet?) 6061-T6
** camshaft, cam chain
** clutch - torque converter
** Catalytic Converter
** Injector Assy, Fuel
** Gasket Kit (engine, transmission, chain case)
** Intake Manifold
** Pump Assy, oil
** plug hole coil
** spool valve
** STARTER MOTOR ASSY(SM-71001)MITSUBA
** Throttle Body 1.8L
** ARM ASSY., ROCKER
** water hose (1.8l)
** water pump (1.8l)
** 5AT Transmission
** 5MT Transmission
** Radiator
** Radiator hose
** ECU 1.8L MT

* Engine Module Least Expensive ~$5232 (Honda Performance Development)
** L15A crate engine
** L15A 5MT
** L15A ECU 5MT
** L15A ignition
** L15A key
** L15A engine harness
** L15A dash harness
** Radiator
** Radiator Fan+shroud+motor
** Radiator hose

* Engine Module More Power ~$8815 (Honda Performance Development)
** Civic Type R crate engine
** Si 6MT
** Hondata ECU
** Civic Si ignition
** Civic Si key
** Civic Si engine harness
** Civic Si dash harness

* Engine Module Frame ~$169 (for 2 units)
** 1.25x1.25x.125" 6061-T6 tube (34.4 feet?)

* Suspension ~$4283 (for 4 units)
** Skunk2 Pro C
** 15x7 MOTEGI RACING SP10 HB
** 195/65R-15 Bridgestone Ecopia EP100
** .25" thick plate, 2'x2' 6061-T6
** strut top mount angle 6061-T6
** 3/8ths x24 grade 8 bolts
** 3/8ths x2 lock nuts
** 1" OD 3/8ths ID steel washers
* (Honda Performance Development)
** Front Knuckle
** Joint F. Ball Lower
** Bearing Assy, Front Hub
** Hub Assy, Front.
** Disk Fr Brake
** Caliper sub assembly, FR
** Pad Set, FR.
** knuckle bolts (BOLT, FLANGE (14X57)) (2)
** knuckle bolt nuts (NUT, SELF-LOCK (14MM)) (2)
** strut top mount nuts (NUT, FLANGE (10MM)) (3)

* Pedal Plate ~$243
** steering column (summit racing)
* (Willwood)
** steering rack
** CMB-14-0010 master cylinder and pedal combo
** ABS block and proportioning valve: WIL-260-11179
** APS229 - Standard Motor Accelerator Pedal Sensors

* Front Crush Zone ~$22
** 6x6x.125" 6061-T6 square tube (9.1 feet?)

* Rear Crush Zone ~$19
** 6x6x.125" 6061-T6 square tube (7.75 feet?)

* Side Crush Zone/Trunk ~$169 (for 2 units)
** 1.25x1.25x.125" 6061-T6 tube (34.4 feet?)

* Body/Aeroshell ~$1107
** polycarbonate (US plastics) (4'x8' x 1/8" sheet)
** nida core honeycomb (NW composits) (4'x8' x 1/2" sheet)
** rivets
* (US Composits)
** 5.7oz Carbon Plain weeve (50" x 18 yards)
** epoxy (54 gal)
** hardner (18 gal)
** 10oz e-glass mat (50" x 18 yards)
** e-glass biaxial mat 1208 (50" x 18 yards)

* Body Top Mount Frame ~$169 (for 2 units)
** 1.25x1.25x.125" 6061-T6 square tube (12.5 feet?)

* Interior ~$823
** carpet 40"x6'
** Autoloc 3 point belt (2)
* (US Composits)
** 5.7oz carbon plain weeve (6)
** epoxy
** hardner
** 10oz e-glass mat (6)
** e-glass biaxial mat 1208 (6)
* (Summit Racing)
** GRT-687 GRANT RACING STEERING WHEEL
** SUM-800600 DIGITAL 6 GAUGE PANEL
** poly seat black 2100 series & cover combo (2)
** DUAL LOCK SLIDING SEAT BRCK PR (2)
** SUM-G1122 COVER & BRACKET KIT SINGLE
** CIP-19100 REPL MIRROR PAIR
** SUM-G2111 seat cover for G2100 seat (2)

* Wikispeedlet ~$271
** 5-1577-4 3.93" STROKE 107 LB. 12 VDC LINEAR A (Surplus Center)
** 5-1577-B LINEAR ACTUATOR MOUNTING BRCKT (Surplus Center)
** Arduino Uno (Maker Shed)
** 12v to 5v converter
** Box, 12"x12"x4".
** PEDAL ASSY., ACCELERATOR (Summit Racing)

* MT Shift Control ~$233
** 5-1577-4 3.93" STROKE 107 LB. 12 VDC LINEAR A
** 5-1577-B LINEAR ACTUATOR MOUNTING BRCKT
** Arduino Uno
** 12v to 5v converter
** Box, 12"x12"x4".

==Chassis==

The Wikispeed car(s) is always evolving, so it's best to start with a piece that hasn't significantly changed in a while. The basic chassis is nothing more than 4" square aluminum extrusion welded into a series of boxes. However, it has a 5-star crash equivalency rating. It is only around $550 in parts and those parts are commodities, so they can be overnighted pretty much anywhere in the world. All you need to build the chassis is an average sized garage, a saw to cut the aluminum, and a welder to fasten it together.

Illustrations are on the way.

BOM
* 4" x 1/8" thick square tube
** 120" long (x4)
** 40" long (x4)
** 12" long (x6)
* Yeah, that's it. That's all the frame is made out of :-)

Project Steps
* Cut aluminum tube to specified lengths
* The only location that needs to be measured
** The center vertical tube is 36" from the inside of the vertical tubes on the open end of the chassis and 72" from the inside of the vertical tubes on the closed end
** Other than that, everything lines up on obvious edges

===From Joe's Notebook===

For the aluminum, we use Coast aluminum over here, and order 500 lbs at a time in stock lengths. This lets us get a discount, and by always ordering whatever length they stock we avoid "cut fee's". For the build, it is ideal to have 3' on each side of parts we are working on. For the chassis, it's 4'x10, so 10'x16' is ideal. The total car, with body, is larger at 6.5'x14', so 12.5'x20' is ideal. It can be worked with far less, however, and I think the ultimate flow of work, when it is optimized, will be to manufacture these inside a shipping container "factory" that can be shipped to wherever the local demand might be.

The jig plates [specifications on the way] are a pre-requite for building the chassis...After each weld, the surface is grounded down (4" electric grinder, or, a coarse file and some hand work) so that the jig plate can be bolted back on flush. At the end, the jig plates are actually other modules- the roll bar mounts and the suspension plates, so they simply have the rest of their components bolted on and now there is a rolling chassis.

Using the jig plates and a 3/8ths centering punch, holes can be drilled to attach the frame to the jig with bolts, then the frame is tack welded, then the jig plates are removed and replaced one corner at a time while the frame is seem welded with the other jigs holding the chassis square as it is heated and cooled during the welding.

The current configuration requires 18.33 KW to bring its 1404 weight plus a 150 lb driver (EPA standard) through the UDDS city test, and 15.11 for the HWFET highway test. However, to meet the X Prize minimums (no-longer required but researched by the X Prize as acceptable minimums for mainstream market interest) our vehicles requires 31.1kw to go from 40mph to 65mph in less than 9 seconds. This is approximately 41.7hp. 50hp or larger gives us a safe target to determine in the drive-train meets our minimums. Please note the current 140hp engine module weighs about 700lbs. That includes fuel, emissions system, cooling system, axles, transmission, engine, engine electronics, data logging, battery, coolant, all fluids, 4 gallons of gas, aluminum engine module cradle.

==Build Steps for Small Volume Scenarios==

===Rolling Chassis===

===Chassis===

* receive in mail or cut and weld on location. http://www.youtube.com/watch?v=YvN8ZF1-ogY&context=C4d5a23fADvjVQa1PpcFNIheMStKChcQuO9z0Bcs9fLnn3W5EWwXM=
* cut and weld on location requires bandsaw set to cut square, jig plates (can be mailed or CNC'd locally), speed square and accurate 48" tape measure with 1/16th" or smaller tick marks.
* If made on site, chassis must then be drilled, requires centering punch, hammer, centering 3/8ths drill bit and drill (drill press or coal drill preferred).

===Suspension Module===

* receive in mail or CNC on location.
* Assemble
* compare to photos for test.
* bolt on to car
* recieve grade 8, 3/8" bolts, washers, and lock nuts
* 9/16ths wrench and socket with ratchet required
* compare to photos for test.

===Wheels & Tires===

* receive wheels with tires and lungnuts in mail (tirerack)
* jack up chassis; set up car jack; put wood block on car jack to avoid scratching frame.
* bolt on wheels; Lug wrench required

===Braking Chassis===

===Pedal Plate===

* receive pedal plate in mail or CNC on location.
* bolt pedal plate onto chassis; recieve grade 8, 3/8" bolts, washers, and lock nuts
* receive brake pedal in mail (willwood)
* receive brake master cylinder in mail (willwood)
* receive accelerator pedal in mail.
* bolt pedals and master cylinder to pre-drilled holes on pedal plate; recieve grade 8, 1/4" bolts, washers, and lock nuts

===Brake Lines===

* receive brake lines in the mail, pre-flared or flare on location; if flaring on location, requires bubble flare tool, metric AND SAE brake line fittings.
* bend lines to match diagram
* receive brake line clips in the mail
* attach clips to existing holes on pedal plate and chassis according to diagram
* screw on brake line fittings; line/flare wrench required, SAE and Metric

===Brake Fluid===

* buy, locally, DOT3 brake fluid; CAUTIION: Brake fluid is one of the few seriously toxic fluids we deal with. Be careful, goggles and latex gloves are suggested.
* fill brake fluid resevoir
* bleed brakes; Requires brake bleeder kit or modified empty water bottle or 3/16th surgical tube.
* Verify brake pressure; Step on brake and verify rock-hard pedal before pedal is fully depressed. Have friends heave on the car and verify car slides before wheels rotate.

===Steering Chassis===

===Steering Rack===

* receive steering rack in the mail.
* receive steering rack mounts in the mail or make locally with CNC.
* bolt steering rack mounts to pedal plate; recieve grade 8, 3/8" bolts, washers, and lock nuts
* bolt steering rack to steering rack mounts; recieve grade 8, 3/8" bolts, washers, and lock nuts
* receive tie rod extendors in the mail or tap locally from hexagonal bar stock.; if tapping locally, need metric tap, I believe M14x1.5.
* receive tie rods in the mail.
* thread tie rods onto tie rod extendors.
* thread tie rod extendors onto steering rack.
* bolt tie rods to steering knuckles.
* verify can heave on front wheel by hand and one wheel does not move at all without the opposite wheel moving.

===Steering Column===

* receive steering column in the mail.
* receive interior module in mail or cut and weld locally; same tools required as making a chassis.
* set interior module in chassis, and bolt in; recieve grade 8, 3/8" bolts, washers, and lock nuts
* receive steering wheel in the mail.
* slide steering column onto steering rack, tighten pinch bolt; metric socket set required.
* attach steering column to interior module.
* Bolt steering wheel to steering rack; SAE socket set required
* verify steering wheel turns both wheels without wobbling.
* align wheels (professional alignment or local with speed square, plumb bob, and level).

===Body On===

===Body Top Mount Frame===

* receive body top mount frame in the mail
* receive button-head hex bolts in mail.
* bolt body top mount frame to car
* receive body by freight.
* set body onto body top mount frame.
* bolt body on to body top mount frame with button-hread hex bolts.
* push and shake body, verify does not flex, wobble, or make noise under force that would dent a fender on a new car.
* dust and polish car body.

==Build Steps for Volume Scenarios==

* Chassis Machining
** extrusions set on templates on aluminum router
** aluminum milling
** test milled aluminum on test fixture (welding jig)

* Chassis Weld
** seam weld along marked paths in welding jig

* Mold Making
** foam on foam router
** foam milling
** test foam on test fixture (CMM)
** send picture from CMM super-imposed over foam photo to customer
** visual inspection and scabbing in

* Composites Layup
** unroll prepreg sheets onto body,
** place core material on router
** test core material on test fixtures
** place core material in mold.
** unroll prepreg sheets over core material
** place thermocouples and vacuum ports in mold
** place vacuum sheet in mold
** place pleats as needed in vacuum sheet.
** test vacuum seal, troubleshoot.
** apply vacuuum

* Composites Debulking
** remove vacuum bag, tensile strength test flashing, take picture and send to customer
** remove from mold, grind off flashing. sand.

* Body Finishing
** place on CNC
** CNC drills body access holes and mount holes
** sand body
** wash body

* Vinyl Wrap
** print vinyl wrap
** unroll vinyl wrap
** apply, squeegee, heat, disperse bubbles of wrap.

* Suspension Corners
** assemble dampers
** adjust dampers
** assemble knuckles
** assemble A-arms to suspension plates with Heim joints
** assemble strut top mounts to plates with bolts
** attach steering kunckles to damper bodies
** attach steering knuckles and dampers to suspension plates
** assemble calipers
** attach rotors and calipers
** place all 4 suspension corners on test fixture

* Engine Module
** assemble engine on engine test fixture (engine cradle)
** attach transmission, longblock components
** attach air intake, exhaust header, fuel system
** test fuel system
** test air system
** test compression
** dyno and fuel consumption test on test jig,

* Electrical Module
** form electrical module box (router, or vacuum form, or composite)
** load PCB on router
** machine PCB
** set PCB on test fixture
** place PCB in electrical module box.
** solder in wiring connections
** pot in wiring connections
** connect wiring connections to RJ45 jacks
** place RJ45 jacks in knockouts on electrical module box
** connect electrical module box to test fixture

* Body Electrical
** insert lights and sensors into body
** attach Cat5e cable to body, connect to lights and sensors
** connect body electrical to test fixture
** see machining, mold, body electrical steps.

* Interior module
* dash panel
* pedal plate
* HVAC system
* stereo
* windsheild wiper and fluid
* door/hinge/clam/latches
* rolling chassis
* cargo spaces/liners/lighting
* wheel wells
* integrated vehicle test
* ABS
* VSC
* tire pressure monitoring
* MILs
* alignment check jig

[[Category:Wikispeed]]

Matt log

2012-04-07T14:31:40Z

Matt Maier:

What I've been up to. [[User:Matt_Maier]]

=Documents & Programs=
*Modular GVCS car concept and the CabCube concept
<gallery>
image:CabCube_concept.jpg
image:Modular_cab_concept.jpg
image:OSE_car_concept.jpg
</gallery>
*Helped summarize and analyze the Feb 2012 [http://opensourceecology.org/w/images/8/8e/Open_Source_Ecology_-_Community_Needs_Assessment_-_February_2012_-_Report.pdf#page=1 Community Needs Assessment]
*LifeTrac Fabrication Report [[File:LifeTrac Fabrication Report 25FEB2012.pdf]]
*LifeTrac Fabrication Draft (version 2)[[File:LifeTrac Fabrication DRAFT 12FEB2012.pdf]]
*LifeTrac Fabrication Draft [[File:LifeTrac Fabrication DRAFT 29JAN2012.pdf]]
*modular vehicle kit suspended and unsuspended rotors
<gallery>
Image:Modular unsuspended rotor frontside.jpg
Image:Modular unsuspended rotor backside.jpg
Image:Suspended rotor frontside.jpg
Image:Suspended rotor backside.jpg
</gallery>

=6APR2012=
*Build [[LifeTrac_III_Definitions]] which is a part of an illustration of how to implement the [[Distributed Collaboration]] process.

=25MAR2012=
*Worked on how to incorporate the [[Connexions]] website into OSE's development/publication process. It is a well established site already, and open source is at the core of its value, so despite not being absolutely perfect it is at least a great start.

=24MAR2012=
*Converted and posted all the current CAD describing Wikispeed's SGT01 vehicle [[Wikispeed_SGT01#CAD]]

=13MAR2012=
*Posted images of concepts related to GVCS modular vehicles in general and the open source car in particular.

=12MAR2012=
*Transferred more Wikispeed STG01 documentation to the OSE wiki.

=10MAR2012=
*Updated the open source instructions for the [[Wikispeed_STG01]] car.

=26FEB2012=
*Summarized the Community Needs Assessment results into [[Community_Needs_Assessment_Volunteers]] and [[Community Needs Assessment Summary]]

=25FEB2012=
*Published the final(ish) draft of the LifeTrac fabrication report. Sent it out for comments and/or approval.
*Updated the [[Distributed_Collaboration]] page with lessons learned and examples from the LifeTrac documentation.

=16FEB2012=
*Sent [[Aaron_Makaruk]] a draft of my distributed collaboration process proposal.
*Created [[Distributed_Collaboration]] to document the method I'm working on for getting from machine prototypes to published reports.

=14FEB2012=
*Incorporated some of Marcin's notes into the tractor report. Also built and added clarifying illustrations.
*Encouraged Expressman to create a "spec sheet" for the tractor that would answer the sort of questions people who are used to dealing with tractors would want answered. [[LifeTrac IV/User's Manual/Spec Sheet]]

=12FEB2012=
*Contacted [http://opensourceecology.org/wiki/Replication/CreationFlame James Slade of Creation Flame] since he's field-testing the LifeTrac.
*Added a lot more to version 2 of the LifeTrac Fab Instructions.
**It seems to be working out that the blueprints should be organized by part/assembly but the instructions should be organized by material/activity. For example, if someone is going to build the thing, particularly if they're going to build it with one or more other people, they'll break up the work by stock material since different stock requires different tools (for the most part). Actually, it would make more sense to organize the build according to tools; have one person at the chop saw, another at the torch/welder, etc...but there's no way to know what kind of tools someone will have or how many. The next closest thing is the "action" like "cut something" and "weld something."
*Exported a draft of version 2 of the instructions so people can see where it's going.

=11FEB2012=
*Uploaded examples of building blocks for the modular vehicle kit. Rotors for low rpm, high weight (unsuspended) and high rpm, low weight (suspended).
*Contacted a custom metal fabricator in Houston.
*Contacted [http://dandhtractors.org/ D&H Tractors] about opening communication. They're high school seniors who are building a LifeTrac for [http://www.southcentralfarmers.com/ South Central Farmers].

=7FEB2012=
*Joined Team Wikispeed and exchanged ideas with team lead Joe Justice on a possible OSE/Wikispeed collaboration.

=6FEB2012=
*Called in to scrum with Lex ([[Daily SCRUM]]). Trying to convince other active developers to invest in some kind of centralized update/discussion process to maximize creativity and generate a team atmosphere.
*Discussed CEBs on the forum.

=5FEB2012=
*Coordinated with Lex about his [[Collaborative Engineering]] project. He is going to upgrade FreeCAD with project management features.
*Added information and [[Lessons Learned]] about Team Wikispeed. They demonstrated how a nominally open source and distributed collaborative engineering project can do seriously impressive things. They produced a street-legal car that gets 100 mpg and a 5-star equivalent safety rating.
*Working on a concept for better machine fabrication documentation. After getting a bit stuck on the LifeTrac fabrication document, and having some time to step back and think, I realized that a dead, isolated document wasn't accomplishing enough goals simultaneously. I am experimenting with the open source and free [http://sourceforge.net/projects/openproj/ OpenProj] (basically a weak version of Microsoft Project) to see if documenting the machine fabrication as a project will better capture diverse pieces of information like time, ergonomics, and resources. Basically, replicating a machine IS a project, so it might as well be documented that way first. I predict that building the fabrication procedure in a project management program will automate the tracking of things like, say, how many bolts the tractor needs. Instead of tediously counting and double-checking, just enter the number of bolts at each step and the program will tally them all up in a report. Changes will be tracked automatically. Additionally, when it's finished people can download the free program, download the free project file, and input their own numbers (like how long it actually took them to do something). It will help them organize their project and it will help the FeF gather important feedback.

=2FEB2012=
*I've been posting on the forum and adding information to the wiki
*Communicating with individuals about the the ironworker and program management/CAD program

=29JAN2012=
*Converted the lifetrac working document into a PDF; it's about an 80% draft based on the information I have now [[File:LifeTrac Fabrication DRAFT 29JAN2012.pdf]]

=27JAN2012=
*Added FPGA rationale and resources
*compiled a list of people to contact re: FPGA-centered [[universal axis controller]]
*Added some specific info on construction vehicle modularity

[[Category:Logs]]

LifeTrac III Definitions

2012-04-07T01:22:38Z

Matt Maier: /* Fittings */

Defining each indivisible piece of a machine is the first step in the [[Distributed Collaboration]] process. The key is that each definition is broken up into "self-evident" units. In short, "self-evident" means that all the information an experienced fabricator would need to make the piece is present in a single file.

It is important not to shoehorn information into the definition that is not strictly necessary. The definition files need to be kept small and limited so that they are easy to change later. If a single tube needs to be made 6" longer and one of the holes moved 6", then only one definition should change and it should be as simple as spitting out a new illustration with slightly different labels on it. If nothing else about the design of the machine is affected by that change, then the definition file can be replaced without changing anything else, even if the machine is well into development and the project and report phases are already humming along. The project step that refers to making that piece won't change because all it said to do was "cut to length" and "drill holes." That the length and hole position changed is irrelevant to the instructions that refer to the definition. In this way changes to the machine design are kept as low-cost (in terms of documentation) as possible. Additionally, even major forkings of the machine design are possible with minimum effort.

Also, whenever possible the definition file should be structured such that it requires no translation between languages. Or, if it does require translation, the words should be simple and unambiguous. Numbers are the best. If they aren't enough on their own, then simple labels like letters are acceptable. If actual words are necessary, then they should be generally accepted terms like "bearing" or "valve."

The best approach is to keep the entire design of the machine in one set of units. You CAN convert the units into their counterparts in another system of measure, but it isn't going to be of much help. For example, the LifeTrac is designed around 4" square tubes. If someone wants to build the LifeTrac with metric parts they are going to have to redesign pretty much all of the measurements because they will be using square tubes that come in round metric numbers, which means all the bolt holes will be offset slightly. This unfortunate situation means that a metric version of the LifeTrac will have to exist side-by-side with an imperial version. They will have to be independent machines. Mixing the designs up together will only create confusion and unnecessary work.

=Overview=
<gallery>
image:Lifetrac_3_front_view_labels.jpg
image:Lifetrac_3_perspective_labels.jpg
image:Lifetrac_3_side_view_labels.jpg
image:Lifetrac_3_top_view_labels.jpg
</gallery>

=Frame=
<gallery>
image:Frame_outer_base_measurements.jpg
image:Frame_inner_base_measurements.jpg
image:Frame_bottom_crossbar_measurements.jpg
image:Frame_a_pillar_measurements.jpg
image:Frame_b_pillar_measurements.jpg
image:Frame_c_pillar_measurements.jpg
image:Frame_top_crossbar_measurements.jpg
image:Frame_cant_rail_measurements.jpg
</gallery>

=Power Cube Mount=
<gallery>
image:Power_cube_mount_measurements.jpg
</gallery>

=Hydraulic Valve Mount=
<gallery>
image:Hydraulic_valve_mount_measurements.jpg
</gallery>

=Loader Arm Crossbar Support=
<gallery>
image:Loader_arm_crossbar_support_measurements.jpg
</gallery>

=Base Cylinder Mount=
<gallery>
image:Base_cylinder_mount_measurements.jpg
</gallery>

=Loader Arm Cylinder Mount=
<gallery>
image:Loader_arm_cylinder_mount_measurements.jpg
</gallery>

=Loader Arm=
<gallery>
image:Loader_arm_measurements.jpg
</gallery>

=Loader Arm Crossbar=
<gallery>
image:Loader_arm_crossbar_measurements.jpg
</gallery>

=Loader Arm Insert=
<gallery>
image:Loader_arm_insert_measurements.jpg
</gallery>

=Tractor Frame Insert=
<gallery>
image:Tractor_frame_insert_measurements.jpg
</gallery>

=Loader Arm Lump=
<gallery>
image:Loader_arm_lump_measurements.jpg
</gallery>

=Loader Arm Shaft=
<gallery>
image:Loader_arm_shaft_measurements.jpg
</gallery>

=Wheel Shaft Mount=
<gallery>
image:Wheel_shaft_mount_measurements.jpg
</gallery>

=Motor Mount=
<gallery>
image:Motor_mount_measurements.jpg
</gallery>

=Motor Interface=
<gallery>
image:Motor_interface_measurements.jpg
</gallery>

=Wheel Hub=
<gallery>
image:Wheel_hub_measurements.jpg
</gallery>

=Wheel Axle=
<gallery>
image:Wheel axle measurements.jpg
</gallery>

=Quick Attach Plate=
<gallery>
image:Quick_attach_plate_measurements.jpg
</gallery>

=Pin=
<gallery>
image:Pin_measurements.jpg
</gallery>

=Hardware=

==Power Transmission==
<gallery>
image:Lock_collar.jpg
image:Flange_bearing.jpg
image:Shaft_coupler.jpg
image:Splined_shaft.jpg
image:Female_splined_coupling.jpg
</gallery>

=Hydraulics=

==Valves==
<gallery>
image:Valve_flow.jpg
</gallery>

==Power Cube Delivery==
<gallery>
image:Power_cube_delivery.jpg
</gallery>

==Power Cube Return==
<gallery>
image:Power_cube_return.jpg
</gallery>

==Drive Control Valves==
<gallery>
image:Drive_control_valves.jpg
</gallery>

==Cylinder Control Valves==
<gallery>
image:Cylinder_control_valves.jpg
</gallery>

==Hose==
<gallery>
image:Hydraulic_hose.jpg
</gallery>

==Drive Power Hose==
<gallery>
image:Drive_power_hose.jpg
</gallery>

==Drive Return Hose==
<gallery>
image:Drive_return_hose.jpg
</gallery>

==Motor Drain Hose==
<gallery>
image:Motor_drain_hose.jpg
</gallery>

==Power Cube Connection Hoses==
<gallery>
image:Power_cube_connection_hoses.jpg
</gallery>

==Loader Cylinder Hoses==
<gallery>
image:Loader_cylinder_hoses.jpg
</gallery>

==QA Plate Cylinder Hoses==
<gallery>
image:QA_plate_cylinder_hoses.jpg
</gallery>

==Cylinders==
<gallery>
image:Loader_cylinder.jpg
image:QA_cylinder.jpg
image:Cylinder_fittings.jpg
</gallery>

==Motors==
<gallery>
image:31cuin_hydraulic_motor.jpg
image:Motor_fittings.jpg
</gallery>

==Valves==
<gallery>
image:2_spool_valve.jpg
image:3_spool_valve.jpg
image:Cushion_valve.jpg
image:Three_quarter_inch_NPT_check_valve.jpg
</gallery>

==Fittings==
<gallery>
image:SAE_4_to_one_qtr_NPTM_nipple.jpg
image:SAE10_to_half_inch_NPT_connector.jpg
image:SAE_10M_to_one_half_NPTF_swivel.jpg
image:Three_qtr_NPT_nipple.jpg
image:Three_qtr_NPTM_90_elbow.jpg
image:Three_qtr_NPTF_tee.jpg
image:One_half_NPT_quick_coupler.jpg
image:Three_qtr_power_beyond.jpg
image:One_qtr_NPT_quick_coupler.jpg
image:One_half_NPT_nipple.jpg
image:One_half_NPTF_tee.jpg
image:One_half_NPT_swivel.jpg
image:One_half_NPT_elbow_swivel.jpg
image:Three_eight_to_one_half_90_swivel.jpg
image:Three_eight_to_one_half_swivel.jpg
image:One_qtr_nipple.jpg
image:One_qtr_tee.jpg
image:One_qtr_elbow.jpg
image:Three_qtr_to_one_qtr_NPT_bushing.jpg
</gallery>

File:Three qtr to one qtr NPT bushing.jpg

2012-04-07T01:22:27Z

Matt Maier:

File:One qtr elbow.jpg

2012-04-07T01:22:11Z

Matt Maier:

File:One qtr tee.jpg

2012-04-07T01:21:53Z

Matt Maier:

File:One qtr nipple.jpg

2012-04-07T01:21:32Z

Matt Maier:

File:Three eight to one half swivel.jpg

2012-04-07T01:21:11Z

Matt Maier:

File:Three eight to one half 90 swivel.jpg

2012-04-07T01:20:48Z

Matt Maier:

File:One half NPT elbow swivel.jpg

2012-04-07T01:20:25Z

Matt Maier:

File:One half NPT swivel.jpg

2012-04-07T01:20:03Z

Matt Maier:

File:One half NPTF tee.jpg

2012-04-07T01:19:46Z

Matt Maier:

File:One half NPT nipple.jpg

2012-04-07T01:19:28Z

Matt Maier:

File:One qtr NPT quick coupler.jpg

2012-04-07T01:19:09Z

Matt Maier:

File:Three qtr power beyond.jpg

2012-04-07T01:18:45Z

Matt Maier:

File:One half NPT quick coupler.jpg

2012-04-07T01:18:27Z

Matt Maier:

File:Three qtr NPTF tee.jpg

2012-04-07T01:17:51Z

Matt Maier:

File:Three qtr NPTM 90 elbow.jpg

2012-04-07T01:17:28Z

Matt Maier:

File:Three qtr NPT nipple.jpg

2012-04-07T01:17:10Z

Matt Maier:

File:SAE 10M to one half NPTF swivel.jpg

2012-04-07T01:15:09Z

Matt Maier:

LifeTrac III Definitions

2012-04-07T01:14:40Z

Matt Maier:

File:SAE10 to half inch NPT connector.jpg

2012-04-07T01:14:26Z

Matt Maier:

File:SAE 4 to one qtr NPTM nipple.jpg

2012-04-07T01:13:51Z

Matt Maier:

File:Three quarter inch NPT check valve.jpg

2012-04-07T01:12:52Z

Matt Maier:

File:Cushion valve.jpg

2012-04-07T01:12:20Z

Matt Maier:

File:3 spool valve.jpg

2012-04-07T01:12:02Z

Matt Maier:

File:2 spool valve.jpg

2012-04-07T01:11:48Z

Matt Maier:

File:Motor fittings.jpg

2012-04-07T01:11:09Z

Matt Maier:

File:31cuin hydraulic motor.jpg

2012-04-07T01:10:29Z

Matt Maier:

File:Cylinder fittings.jpg

2012-04-07T01:09:46Z

Matt Maier:

File:QA cylinder.jpg

2012-04-07T01:09:27Z

Matt Maier:

File:Loader cylinder.jpg

2012-04-07T01:09:10Z

Matt Maier:

LifeTrac III Definitions

2012-04-07T01:08:10Z

Matt Maier:

File:QA plate cylinder hoses.jpg

2012-04-07T01:07:59Z

Matt Maier:

File:Loader cylinder hoses.jpg

2012-04-07T01:07:42Z

Matt Maier:

File:Power cube connection hoses.jpg

2012-04-07T01:07:20Z

Matt Maier:

File:Motor drain hose.jpg

2012-04-07T01:07:03Z

Matt Maier:

File:Drive return hose.jpg

2012-04-07T01:06:45Z

Matt Maier:

File:Drive power hose.jpg

2012-04-07T01:06:30Z

Matt Maier:

File:Hydraulic hose.jpg

2012-04-07T01:06:17Z

Matt Maier:

LifeTrac III Definitions

2012-04-07T01:03:30Z

Matt Maier: