1st crash.

BigglesPiP · 6 Jun 2010 at 19:21

No, not the Alfa.

Today we tested the Formula Student car, I was the second to drive it after we made a large number of alterations. Half way round the second lap we did a Buemi, the rose joints holding the left front upright to the wishbones both failed. The wheel departed and I went sliding along the grass with the car on the floor. Getting out I noticed a drive shaft had snapped, so I actually had no brakes: Front circuit was open because the calliper was running away with the wheel, the rear was useless because it's a single disk on the diff, and the shaft had failed. Didn't hit so much as a cone, I have no desire to test the impact attenuator.

There are photos, which I will get hold of and post tomorrow.

Before the crash it was going quite well, there are niggles - such as it being almost impossible to change gear - but it handles really well, there's a lot of power which is delivered very smoothly (80bhp / 250Kg = 320bhp/ton), it's easy to control with a lot of power on too.

Oh, an it was wet. Lots of work to do this week now to get out and test again on Sunday. But it's better to find out it's too weak with 6 weeks left to the race. Gave the Golfists at Aintree a good scare too.

jr1104 · 6 Jun 2010 at 19:39

Unlucky, but like you said better to find out now. Which uni are you at?

Souleh · 6 Jun 2010 at 20:30

What engine is in it? Surely a bike engine could be planted in for mucho extra bhp unless theres rules against it!

griffo_001 · 6 Jun 2010 at 20:45

Souleh said:
What engine is in it? Surely a bike engine could be planted in for mucho extra bhp unless theres rules against it!

600cc max capacity and an air restrictor are the main rules that choke the power. You can do what you like to the engines, but generally you keep it simple unless you want your car to explode in the endurance event

Most common engine seems to be the CBR 600 engine, they're bullet proof and fairly powerful - weigh an absolute tonne tho

We use an Aprilla SXV/RXV 550cc engine for its V-Twin lightness

commited · 6 Jun 2010 at 20:59

When I was involved with the Formula Student, single cylinder engines seemed to be favoured by most teams!

Simon · 6 Jun 2010 at 21:49

commited said:
When I was involved with the Formula Student, single cylinder engines seemed to be favoured by most teams!

Still are I think - my mate is now a judge.

I managed to crash our car at the competiton, nearly rolled it hitting a cone.

BigglesPiP · 6 Jun 2010 at 22:34

So I'm not the only one to crash one of these then. We use the CBR600RR motor with a custom intake and re-baffled sump, other than that it's a standard engine.

I'm with Liverpool John Moore's University. We were only a week later than we planned to test in January. We're actually quite happy with the amount we've learned and how little needs changing, just that one of the things is a bit fundamental and made a wheel fall off under me. I still feel like **** for breaking the car, the 2 other drivers who were about to be stuffed in for 3 laps each were a bit frustrated.

Simon · 6 Jun 2010 at 23:18

We finished ours about 30mins before it went on the trailer to the competition. Daytona 600 engine

Testing is overated

griffo_001 · 6 Jun 2010 at 23:21

Simon said:
We finished ours about 30mins before it went on the trailer to the competition. Daytona 600 engine

Testing is overated

My thoughts exactly. Stuff breaks when you test it

We blew up a rear suspension mount last year on the rolling road

It was a really complex part that was outsourced for production and the idiots made it out of a steel that was much to weak :rolleyes:

K.C. Leblanc · 6 Jun 2010 at 23:54

BigglesPiP said:
I'm with Liverpool John Moore's University. We were only a week later than we planned to test in January. We're actually quite happy with the amount we've learned and how little needs changing, just that one of the things is a bit fundamental and made a wheel fall off under me. I still feel like **** for breaking the car, the 2 other drivers who were about to be stuffed in for 3 laps each were a bit frustrated.

Just think how you'd feel if it was a driver error.

griffo_001 · 7 Jun 2010 at 10:25

What are you guys using as brake lights by the way?

I found an old fog light in one of the cupboards full of old bits that will do the job, but was also contemplating some LED special to save a bit of weight. My only worry with the LED root is the rule that it "must be clearly visible in daylight" or something equally non-specific. Interestingly regular lights have no such requirement :confused:

Simon · 7 Jun 2010 at 10:47

Err a proper brake light.

Remember there is a design event, bought in parts are ideal.

Morbius · 7 Jun 2010 at 10:51

If I remember rightly, ****** stock a proper rain light for quite a bit less than the parts companies charge for an identical part.

Edit: Oops, mentioned a competitor. Sorry

Dogbreath · 7 Jun 2010 at 10:53

BigglesPiP said:
No, not the Alfa.

Today we tested the Formula Student car, I was the second to drive it after we made a large number of alterations. Half way round the second lap we did a Buemi, the rose joints holding the left front upright to the wishbones both failed.

I've seen this happen on another Formula Student car, and I'm struggling to remember which team it was. They had used minuscule 8mm joints IIRC.

BigglesPiP · 7 Jun 2010 at 13:56

Apparently Oxford Brooks did the same thing in Detroit the other week. We had 10mm joints which had been subject to welding temperatures.

Anyway, as promised:

Teh car.

A wheel.

I take Jack through the startup.

The 1st time the car has moved under its own power, it's horrid to drive at this point, gearshifts are impossible.

After some alterations it's better, shifting is still hard, Jack seems to be having fun:

Ignore the spin, the car is performing very well, it's hugely controllable on the power.

After a few modifications to the throttle I get in.

The thing can tripod at both ends it seems.

And then it all ends with a bang as I touch the brakes. I trundled onto the grass with no brakes at all.

-

So, yea, we're changing those for 3/4 imperial roses and we're going to re-make the arms so the top and bottom ball joints can have no thread exposed, we're not welding with them in and we're taking the Camber adjustment to the inside. Then we're letting the next driver who was just about to jump in after me do about 5 brake tests back to back. Must dash, car to mend.

griffo_001 · 7 Jun 2010 at 18:18

Well least yours is up and running - our Aprilla's are being nothing but trouble

Stupid Italian engines

On the plus side the front suspension went on today and its starting to look more like a car and less like a boat

SB118 · 7 Jun 2010 at 18:28

BigglesPiP said:
The thing can tripod at both ends it seems.

Would that be some inlet pipe collapse i spy?

Simon · 7 Jun 2010 at 20:46

Tyres grip better when they are on the floor

Get some more droop in it

BigglesPiP · 7 Jun 2010 at 22:14

SB118 said:
Would that be some inlet pipe collapse i spy?

Good eye, it certainly is.

Simon said:
Tyres grip better when they are on the floor

Yea, the springs were wound tight to the point where there is no droop at the rear. We have some stronger springs we can use without winding them tight, should help.

Simon · 7 Jun 2010 at 22:24

Who designed that inlet system, it's horrible.

So many failure points, soft pipes between an engine and restrictor is just asking for trouble.

The manifold could do with a bit of CFD too.