Construction
Most components will be 3D printed. This allows for easy prototyping and test fitting for many of the components. Each part begins with a test print of 15% infill, a 2-layer wall, and a honeycomb pattern. After much testing and fitting for parts. The components will then have corrections made based on the previous testing. Most issues came from the misalignment of holes and wrong hole sizes. This was mostly due to shrinking that was then corrected before making the final print. Each component had its settings for infill and wall layer, but most components did use a cubic pattern with a 40% infill and 6-layer wall. These settings can be found within the report, as the printing settings are specified within the corresponding drawing of the part.
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Some additional issues occurred when first making the test prints. Many of the prints had issues with adhering to the bed. This issue was solved by increasing the bed temperature from 60 C to 65 C. Allowing for the filament to further seep into the grooves of the bed. Solving the issue, which then would be implemented to all prints.
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As for the wishbones, things went smoothly as 3D-printed parts were made for testing the fitting of the components. Some design alterations were needed as the upper wishbones over-extended causing the wheels to toe in. After the components were successfully fitted, the drawings were then sent to Send-Cut-Send to be laser cut with 6061 Aluminum. The part was then deburred, tumbled, and the appreciated holes were drilled once receiving the parts, as shown in Figures 2 and 3.
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The parts were then given a finish, by oxidizing them in Antique Black solution. This adds a "rust" effect to the aluminum resulting in a thick layer of corrosion. This layer was then brushed off a wire brush giving it the desired wear look, as seen in Figure 6.
Drawing Assembly Tree
Figure 1: Assembly Tree
Wishbone
- Wishbone Manufacture
Figure 2: Drill Pressed Holes To
Wishbone
Figure 3: All 6061 Aluminum Wishbones
Once the parts were received from Send-Cut-Send, the laser-cut parts needed to be deburred, drilled, and tumbled.
- Wishbone Oxidizing
Figure 4: Solution Used to Oxidize Wishbones
Figure 5: Wishbones in After Solution Was Brushed On
Figure 6: Wishbones After Brushed With a Wire Brush
The wishbones were cleaned from tumbling residue, oxidized, and then wire brushed to give a cleaner look.
Front Assembly
- Assembling Front Suspension/Steering
Figure 7: All Parts of Front Assembly
Figure 8: Top View of Front
Assembly
Figure 9: Front View of Front
Assembly
Video 1: Time Lapse of Assembly of Front of Suspension/Steering
This YouTube video consists of a time-lapse of the front suspension/steering being assembled. The original video was 1 hour and 15 minutes, while the time-lapse condensed it down to under 5 minutes.
Rear Assembly
Figure 10: Rear View of Rear Assembly
