1st crash.

Simon · 24 Jun 2010 at 20:48

Full Carbon monocoque chassis with 2 layer carbon side pods (350grams each).

Notice the plastic roller barrel throttle body too

BigglesPiP · 24 Jun 2010 at 20:53

griffo_001 said:
I just noticed something: You're using a re-baffled sump? Is it still the wet sump as per the bike? Back when we used the CBR (And now with the Aprilla) we had to switch to a dry sump to avoid oil starvation during cornering.

We've just re-baffled it, the way we've done it it's almost a tank. The pick-up has been lowered and a plate installed above that, the pressure valve return squirts excess oil below the baffle. We've copied what a Side-car racer using the CBR600 does.

griffo_001 · 28 Jun 2010 at 23:04

Just found this:

http://www.youtube.com/watch?v=XJL4-wGPjCo&NR=1

:eek:

Fuzz · 28 Jun 2010 at 23:32

Well you are doing better than some welsh uni at this. That one has yet to turn up at our place in a state in which it can be power tested / run / tuned.

I do wonder sometimes where we are going to be with technology in years to come when the youth of today can't manage to even feed themselves unless it involves pot noodle

griffo_001 · 28 Jun 2010 at 23:39

Scubascorpion said:
Well you are doing better than some welsh uni at this. That one has yet to turn up at our place in a state in which it can be power tested / run / tuned.

That would be us

It usually shows up ready be run and tested... it just breaks.... quickly

Moral of the story is never buy "rebuilt" Aprillia engines when you can't see the bikes they came from :rolleyes:

Yes Corsa Italiana I'm looking at you

BigglesPiP · 29 Jun 2010 at 18:16

The moral of the story for Formula Student is never buy Aprillia engines from what I hear. KTM is a mistake too.

Fuzz · 29 Jun 2010 at 19:08

griffo_001 said:
That would be us It usually shows up ready be run and tested... it just breaks.... quickly

Moral of the story is never buy "rebuilt" Aprillia engines when you can't see the bikes they came from Yes Corsa Italiana I'm looking at you

I thought the last issue wasn't the engine so much as the way the suspension was bolted to a bit of honeycomb board.

I said in the morning "surely that needs a brace accross it as all the load from the suspension goes through it"

"No, no, it's been stress calculated"

Couple of hours later when the exhaust warmed it up...

"CRUUNCH"

Ahh..... See you in a couple of weeks then lads

griffo_001 · 29 Jun 2010 at 19:16

True, new chassis since then though.... and a lot of heat shielding

I don't think the heat was taken into account in the design, and the ceramic coating on the exhaust should have kept the heat in anyway, but clearly didn't

Been testing at Llandow past two days, it runs almost reliably now :eek:

Just need to bed the brakes in properly and/or make them stop better, secure the clutch cable better and we'll be back there on Thursday

Fuzz · 29 Jun 2010 at 19:29

You mean it actually starts on command now !!!

griffo_001 · 29 Jun 2010 at 19:30

I wouldn't go that far

One of the main problems was that it never ran enough for the alternator to recharge the battery so we've knackered a series of batteries trying to start it, but now we're doing longer runs that seems to allow time to recharge

Fuzz · 29 Jun 2010 at 19:41

But you always had a start and charge on it when it was at work, all that did was burn out starter motors and the starter ring gear thing inside.

And it still didn't start.

griffo_001 · 29 Jun 2010 at 19:50

Yeah I'm not convinced this battery can supply the power required to start the thing at all

but if you jump start it it runs perfectly and starts easier than when it was on the Start and Charge :confused:

BigglesPiP · 29 Jun 2010 at 20:42

griffo_001 said:
I wouldn't go that far

One of the main problems was that it never ran enough for the alternator to recharge the battery so we've knackered a series of batteries trying to start it, but now we're doing longer runs that seems to allow time to recharge

Varley gave us their smallest Red Top for free, that thing can crank our Honda till the cows come home and then go to the shops for some milk.

Fuzz · 29 Jun 2010 at 21:00

Any of you lot go to the Autosport show back in Jan.. some of the erm "better" examples were there. :eek:

DaveyD · 29 Jun 2010 at 23:11

griffo_001 said:
Just found this:

http://www.youtube.com/watch?v=XJL4-wGPjCo&NR=1

That happened to a team on one side during the endurance at Germany last year, one of their machined wheel centres was a little bit too thin, wheel broke under braking, nearly hit Pat Clarke!

If you want some extreme FSAE stupidity, have a watch of this! :

http://www.youtube.com/watch?v=lLhHAR3jhrc

Looking forward to FSUK this year, second year of judging, might even be judging a few of you!

Dave

DaveyD · 29 Jun 2010 at 23:17

BigglesPiP said:
That's some sweet bodywork.

We have all the parts for 8 new wishbones now, the lower ball joints are spherical bearings. We've tested a couple of times since the crash and we're consistently bending rear lower roses. Welding the new ones up tomorrow.

Also; we all hate Percy, when we're done we're going to burn him. Our headrest now looks a lot more like yours, position I mean.

Percy is a nightmare, but you've got to be very careful with it, as you wont be allowed to even drive if you don't meet the standard. If you are still struggling, drop me an email in trust and I can probably give some suggestions (I was a scrutineer and judge last year, but not scrutineering this year).

Dave

griffo_001 · 29 Jun 2010 at 23:23

How else do you plan on testing an impact attenuator?

My Dad was planning on judging the design section this year too, but other things have come up, so I'm not sure what's going on there :rolleyes:

As for the templates, have you noticed how giant our car is :eek:

it must be twice the height off the deck of the cars we had before he grew fat

DaveyD · 29 Jun 2010 at 23:26

BigglesPiP said:
Ah, yes, we have a plan regarding that. There will be new uprights designed to take larger rose joints (3/8 imperial instead of M8, I think) with no threads exposed. The inner end of the wishbones will point the roses directly at the chassis, so they can do the camber adjust. The wishbones will also be made to a finer tolerance, the current ones are rubbish.

Have a read of Pat Clarke's column on rod ends in bending, in fact if you get bored and have a free few minutes, read all of his columns on the FSG site, will help in design a little.
http://www.formulastudent.de/academy/pats-corner/advice-details/article/pats-column-rod-ends-in-bending/

DaveyD · 29 Jun 2010 at 23:28

griffo_001 said:
How else do you plan on testing an impact attenuator?

My Dad was planning on judging the design section this year too, but other things have come up, so I'm not sure what's going on there

As for the templates, have you noticed how giant our car is it must be twice the height off the deck of the cars we had before he grew fat

Cardiff Uni I guess? You guys love your ally sandwich panel chassis don't you! (I'm assuming that's what it is still? Or something like that anyway).

It's a bit of a tough one with the rules on percy combined with seat angle and template rules, but you still get some tiny cars that just about manage to pass without looking too big.

BigglesPiP · 29 Jun 2010 at 23:53

Rod end issue is solved I think, all the bottom ball joints have been replaced with spherical bearings now. I'll try and get a photo.

The mad Vicar was with us at our last test, he was quite surprised we managed to bend them as we re-built the rear suspension after each run. For some reason - just before we made the new arms - we were consistently bending rears, but not touching the fronts. I think the front two I broke in the very 1st test had been in place near a lot of welding.