GCSE RESISTANT MATERIALS COURSEWORK

measlyincompetentUrban and Civil

Nov 29, 2013 (3 years and 9 months ago)

84 views

GCSE RESISTANT
MATERIALS

COURSEWORK

By

Nathaniel Olson

The Design Brief

Nathaniel Olson GCSE Resistant Materials

Below is the design brief:






I would be making a Greenpower kit
-
car. Greenpower is a
charitable organisation that runs a series of races in the UK for
school
-
built electric cars. Many schools would like to participate in
these races, but lack the basic expertise to built a car from the
ground up. This is my target market; a kit
-
built car for schools that
could campaign a car and make modifications, but want a sound
base to work from. The car will be largely built from wood, to
promote the sustainability and ecological ethos of the Greenpower
organisation.

Target Audience

Nathaniel Olson GCSE Resistant Materials

This would be aimed at secondary schools that want to be
involved in Greenpower, but lack the experience, knowledge
and the equipment to do so. Also this would be more attractive
to the pupils that come from feeder schools which have been
participating in the Goblins. The pupils that are interested in
engineering and racing need a kit
-
car that is competitive,
because the current kit
-
car that is being supplied by
Greenpower is uncompetitive in most cases and extremely
heavy.

As a fact, there are more Goblins in the South West than any
other region.


Task Analysis

Materials

Nathaniel Olson GCSE Resistant Materials

Wood


Organic, non


toxic, energy efficient, 100% environmentally friendly, biodegradable,


It’s re
-
useable, recyclable and renewable in your lifetime.


Wood is tough due to the fibres in the grain but can snap if bent too far.


Strong in compression and very light.


For bending: soak, steam or laminate.


Easy to mark, cut and join. Can be easily shaped.


Join by jointing, gluing, screwing or bolting.


Steel:



It’s strong, hard wearing, heavy, malleable,
machinable
.



Can be cast into complicated shapes when heated a high temperatures.



Using heat to bend, roll or shape is called forging.



Join together by solder, brazing, welding, bolts or rivets.



What I am going to use for Materials
and Finishes

Nathaniel Olson GCSE Resistant Materials


I chose plywood for my project because it comes in broad flat sheets which are very
strong, it can be painted or varnished.


It is sustainable because it is made from commercially forested wood and has little
waste. It is also
biogradeable
.


I chose to use a solvent
-
based paint to protect the chassis. This isn’t a sustainable
finish as it forces the car to be unrecyclable and have to go straight to landfill sites.
However because it should protect the car so well that it wouldn’t need to be
replaced for a long time.

Joints

Nathaniel Olson GCSE Resistant Materials

The joint on the left is a
good permanent effective
joint. Once it’s glued with
PVA or other glue, it
cannot break easily. This
joint is designed for
strength.

The joint on the left is an
easy to make common
woodworking joint that is
usually seen in furniture.
The strength is not as
great as the mortise and
tenon

joint.

MORTISE AND TENON

CROSS HALVING

BRIDLE

This is a similar joint to the
mortise and
tenon

, except
there is an opening at the
corner which means that it’s
weaker. This can be
replicated along the edge
to form a structure.

Design Specification

Nathaniel Olson GCSE Resistant Materials

DESIRABLE



Low as possible to make it more aerodynamic


Make it narrow as possible to make it more aerodynamic


Structural rigidity (
torsional

and longitudinal) . This will improve the car’s handling


State
-
of
-
the
-
art steering geometry


to improve handling for new drivers and improve safety


Target weight distribution of 50/50 front to back to improve handling


As most of the car will be made from sheet materials, optimise design to fit on the minimum number of sheets.


To provide the metal components (steering and
drivetrain
) in a pre
-
assembled form for schools that lack the ability to weld.


Minimum number of components


MUST


Must fit the regulations set by
Greenpower

(See in two slides)


Be able to fit wide range of people into it.


To be built largely from wood or other sustainable/recyclable materials.


To be designed to take advantage of modern computer controlled manufacturing techniques such CNC routing and
waterjet

cutting. This will reduce
costs, increase manufacturing accuracy, and keep material waste to a minimum.


Will be easily modified by student clubs to their preferences


Have the ability to put a aerodynamic body over it


Be easily repaired after a crash


To provide instructions/documentation that show how the car is assembled, and the design principles behind the car. This all
ows

the school to use the
Greenpower

car as part of the curriculum.

Greenpower

Regulations 1

Nathaniel Olson GCSE Resistant Materials

Batteries


T2.6. Batteries must be separated from the driver by a bulkhead, or contained in a rigid,
covered, ventilated box, which must not be able to short circuit battery terminals. Batteries
must be located within the bodywork of the vehicle.

Wheel & Track


T3.1. Tyres must not be less than 300mm or greater than 520mm in diameter.


T3.2. There must be four wheels located as a matching front and matching rear pair,
symmetrically about the centreline of the vehicle.


T3.3. The track of the vehicle must not be less than 500mm front or rear. The track is deemed
as the measured width between centres of tyres where they contact the ground. The track may
vary front to rear.


T3.4. Tyres must be pneumatic.

Centre of Gravity


T4.1. The base of the batteries must be at or below 100mm from ground level. A 6mm
diameter hole should be drilled through any solid floors adjacent to the batteries to allow
height measurement.


T4.2. The driver’s seat including any padding must be at or below 100mm from ground level.
A 6mm hole should be drilled through the base of the seat to allow height measurement.


Greenpower

Regulations 2

Nathaniel Olson GCSE Resistant Materials

Dimensions


T5.1. The vehicle must not exceed 2800mm in length, 1200mm in width, and 1200mm in height.


T5.2. Ground clearance must not be less than 30mm.

Seating


T6.1. The vehicle will have one seat firmly fixed to the vehicle chassis for the driver who will remain seated at all times w
hil
st
racing.


T6.2. The driver must be seated in a conventional feet forward, head to the back position. Drivers may not kneel, sit astride

a
seat, or lie down in any way such that their chests and head are forward of their waist.


T6.4. There must be a solid floor under the whole of the driver.


T10.4. The vehicle must be fitted with a minimum four fixing point, 50mm width safety harness, with secure fixing points on t
he
roll bar or chassis. Harness shoulder strap fixing points should be close to shoulder height and neck width. Lap straps must
be
able to be fully tightened before shoulder straps and must fully tighten around the driver’s lap without additional padding i
n
front of the driver.


T10.5. Drivers in low reclined seating positions with a raking angle of less than 45 degrees if the seat has a flat base, or
30
degrees with a front angle of 15 degrees will require a five or six point safety harness.


Greenpower

Regulations 3

Nathaniel Olson GCSE Resistant Materials


Bodywork/Chassis


T7.1. The vehicle will have bodywork reaching to at least the back of the driver, and at the sides must always cover the
elbows of the driver. Bodywork must not prevent hand signals from being made.


T7.2. There must be a permanent cockpit opening, large enough for the driver to exit the vehicle, without the use of doors or

the movement or removal of any panels or coverings.


T7.5. Medium
-
high density energy absorbing flexible closed cell foam of minimum 25mm thickness must be attached down the
cockpit sides to protect a substantial part of the driver’s body, from the floor to the cockpit opening.


T7.6. There must be a structural cage around the driver’s position. External bodywork either side of the driver’s body to a
minimum height of 250mm from the seat base, or elbow height if above this level, shall be of rigid material such as aluminium
,
rigid plastics, carbon fibre,
grp

or other composites of at least 1.5mm thickness. Plywood needs to be a minimum of 3mm thick.
Corroflute

type material or foam on its own is not permitted for this area. This bodywork shall be lined internally with foam as
per regulation T7.5.


T7.7. There must be a solid bulkhead forward of the driver’s feet in the front of the cockpit, with 100mm depth of medium
-
high density energy absorbing flexible closed cell foam forward of this bulkhead, to protect the driver from frontal impact.


T7.9. Bodywork must not prevent
scrutineers

being able to check the integrity of steering linkages, wheel bearings and wheel
security. Vehicles must be able to have these items exposed during
scrutineering
.


Greenpower

Regulations 4

Nathaniel Olson GCSE Resistant Materials

Roll Bar


T9.1. The vehicle must have front and rear roll bars offering protection in accordance with the diagrams shown here


the
helmeted head of all drivers must be at least 50mm below the line A
-
B as shown.


T9.2. Roll bars must be firmly secured to the chassis of the vehicle. At least one triangulated brace must be fitted to the r
ear

roll bar. This brace should attach to the chassis of the vehicle at one end, to not more than 200mm from the top of the roll
bar

at the other, and must be capable of taking forward and rearward loadings.


T9.3. Aluminium or steel roll bars are to be used and must be strong enough and of sufficient dimensions to perform
satisfactorily. If in doubt check material suitability with
Greenpower

before construction. Composite roll bars are not
permitted.

Steering


T11.1. Steering systems must have minimal play in joints. Control rod geometry must not be able to over centre.


T11.2. Steering must be by mechanical linkages only.


T11.3. Steering must be by front wheels only.


T11.4. Steering must be operable by hand only.



Inspiration

Nathaniel Olson GCSE Resistant Materials

Rotary Racer

Nathaniel Olson GCSE Resistant Materials

Inspiration

2

The back end is what I am interested in. The motor, roll
bar and back cross axle are all connected to one piece.
This is then bolted to the chassis. This is an easy way of
doing the motor, roll bar and back cross axle.

Richard Lander Racing

Nathaniel Olson GCSE Resistant Materials

Inspiration 3


The battery box on the
left is a good way of
doing it. It is sitting on
rails so when the driver
gets out, they slide the
battery box out and
change the batteries.
Then they slide it back
in. The advantage of
this is that there is no
opening to get the
batteries in and out
and this gives it a
aerodynamic
advantage. But this
means that the driver
must get out before
changing the batteries
which means slower pit
stop.

Penair

School


Raptor Fusion

Nathaniel Olson GCSE Resistant Materials

Inspiration 4

The picture on the
right shows the jagged
teeth on the bottom of
seat. This inserts into
the jagged teeth on
the left and makes a
adjustable seat.



Penair

School


Raptor Fusion

Research Plan

Nathaniel Olson GCSE Resistant Materials

What

do I need to find out?

Where

do I find it?

How would

it help me?

What is the average school

technology department best
equipped to do?

Interview

This would tell me what
materials I should

make it out
of.

The

main thing that a kit car has to
do?

Interview

I would

need to decide what
my car would need to do.

The

size of the biggest driver and
smallest driver.

Interview

It

would help me to design the
car around a wide range of
people.

What form would the club like to
recieve

their kit
-
car?

Interview

When

selling the kit
-
car, I need
to know how they would want
to receive the kit
-
car

How much

would they spend on a
kit car?

Interview

This is to help me

to build the
car within the parameters

Product Analysis #1

What materials have been used to make it?

The materials are super light steel and plywood. We used steel
because it’s very strong and versatile. After making the chassis, wood
was required to fill the gaps so the driver can sit in it. We also used the
wood as a board where we can fit electrical wires and devices.

What processes could be used to make it?

The car is made by brazing and welding.


Advantages:

You can very easily change the shape or add parts onto it.

Can be light

Disadvantages:

The high heat of this car can cause a twisted frame or a distortion of
the metal

Would need equipment that is dangerous and hard to learn.

More expensive.

Is the steering any good?

This car has a lot more steering than is required in Greenpower
racing. The track is very big and has big corners that does not
require a great degree of turning. This affects the overall size of the
body and chassis. The only use of the extra degree of steering, is
navigating around the Greenpower paddock and the pit
-
lane and
getting out of the classroom.

What sort of body shapes work and why? How does that
affect the chassis?

The body shape is crucial in the performance of the car, so the body
needs to be long, thin and low in order for the car to cut through the
air efficiently. So the chassis would need to have that ability to be
aerodynamic. Unfortunately this car is very wide and high off the
ground so immediately the car has a big disadvantage.

Is the positioning of the battery box any good?

The battery box is under the seat to help the weight distribution and
the handling . If we put the battery at the front of the car, it would
make the handling horrible.

Is the positioning of the seat any good?

The seat is in the right place except the angle is wrong. The seat is
very upright compared to the way it should be. If the seat is flatter, it
would improve the aerodynamics, as the driver is lower, therefore
we can make the body lower.

In order to make the car thin to make it more aerodynamic, the back
wheels would need to go behind the driver and the front wheels need
to be tuck right next to the legs.

Penryn

College

Hot Ice

Product Analysis #2

What materials have been used to make it?

The material is carbon sheets with a honeycomb core in between. This
makes a super light, super strong car. This is used for the majority of
the chassis. The steering linkages are made of metal. The roll bar is
also made of aluminium as it’s required.

What processes could be used to make it?

This car is glued together with epoxy resin. This is an harmful
substance to use and a parent must have done it away from the school.

They would’ve need to use this substance as they are using carbon
fibre with as honeycomb core which is a hard material to glue together.

The advantages of this is the strong end product that won’t come apart
easily. The epoxy resin helps to the make the car lighter as well.

The disadvantages of this method is the substance itself that has been
used to glue the car together.

Is the steering any good?

The car, visually has barely no steering, but it does have enough
steering to drive around the track which is the objective. The car has
a 11 metres turning circle so it’s more manoeuvrable than a ordinary
car. The disadvantages of this is that the car has to be lifted around
to get out of class rooms, or tight spaces in the paddock. The small
degree of turning helps them to have a smaller body which makes
them faster.

What sort of body shapes work and why? How does that
affect the chassis?

The body is hugely critical in the performance of the car, so the body
needs to be long, thin and low in order the car to cut through the car
efficiently. So the chassis would need to have that ability to be
aerodynamic. This does exactly that, so this is a good car to be
aerodynamically good, and this show in the national final where they
came 4
th

out of 75 cars.

Is the positioning of the battery box any good?

The battery box is one of the good features of this car because, it’s
built on a set of rail, so when the driver gets out, it can slide out. This
enables the car to have no hatches on the body which gives them a
aerodynamic advantage.

Is the positioning of the seat any good?

There is no seat in this car because there is no space for it. This
makes it unconformable to drive in. The driver’s position in this car is
right, He/she would lying down, with the majority of their body laying
on the floor with the head leaning forwards toward the front so
he/she can see out of the car.

Penair

School

Raptor Fusion

Interview with Chris Parker

Nathaniel Olson GCSE Resistant Materials


I had an interview with Chris Parker, a Director at Inspired Cycle Engineering, who mentors the Greenpower club at
Penair

School. I have worked part
-
time at I.C.E.


We discussed his ideas for a light, easily built chassis.


First, he talked to me about the construction of the lightweight car. He sees a main structure which has two 4x2
wooden posts on either side of the car. The two cross axles (supplied by ICE) would be attached to the two posts via
block of wood attached to posts. Then the roll bar would be bolted to the wooden posts. So the posts are crucial as
everything on the car would be attached to them. There are a small number of bulkheads which give the box it’s
basic shape, and a sheet of bendable material which wraps around the bottom of the car and attaches to the 4x2’s.
The driver would lay inside this folded material.


He talked about the steering, which consists of a similar system to the one that ICE uses on their trikes. It uses a
handlebar from a bike attached to a bike stem and that would rotate round a pivot. That would be linked with two
track rods, one for each wheel. They would be attached to the edge of the handlebar to the kingpost (rotatable
mounts for the wheel). This is a basic steering system that is easy to build. Also on the handlebar, he said you can put
two brake lever on it, one for brake and one for turning the motor on/off. The ends of the handlebar could be used
for other options.


We also talked about the battery and motor layout. Firstly between the two timber posts at each side, there would
be a partition behind the driver, and one at the back of the car. Between the two partitions, there would be pieces
of wood spanning the gap and that would be where the batteries and motor would go. The batteries would have a
lid which would rotate on a pivot; built into the lid is the contacts. The reason why there aren’t any plugs or wires is
to improve reliability and reduce the maintenance on the batteries and car between each race.

Interview with Chris

Nathaniel Olson GCSE Resistant Materials


He talked about the centre of gravity and the weight distribution and how that would improve
the handling and the load on each wheel. I need to consider this as it would determine the
position of the front wheels. Ideally the weigh on each wheel should be the same


a 50
-
50
distribution between the 2 axles. It is also important to keep the weight out of the end of the
car, as it affects the handling (how quickly the car can turn and how easy it is on it’s tyres) and
how the car handles bumps (weight in the ends can cause pitching, which can change the
loading on the wheels)


Then he went on about the importance of aerodynamics compared to the importance of
weight of the car. The main point that he was trying to make is that the aerodynamics is vital
and making a light car is although important, but it doesn’t affect the car in the way that
aerodynamics does. He then gave me a sheet which explained the point that he was trying to
make. One thing that surprised me the most, is that the 3 times winner Rotary Racers, their car
weighs 75 kg which is significantly heavier than the most of the field and this shows the
aerodynamics is crucial to doing competitively.


Then we went back to the car and talked about the gearing and what would be the best way
of setting it up. He suggested that mounting the cassette on the motor shaft would work with a
derailleur shifting the gears around. This reduces the amount of strain put on the system, and
reduces the length of chain being used and therefore less to break. Then I suggested a system
that I thought that would be used in a lot of car all of the country.


Interview with Chris

Nathaniel Olson GCSE Resistant Materials


Summary


Basic car built of 4x2 with attached structures for the steering and the drive system is a good idea. The
bent material forming the main part of the body may not be the best idea. It limits the shape of the car to
a cylindrical or conical shape that can be bent from sheet material. It might be better to construct a coffin
-
like box from several panels that would allow some control over the final shape, especially if the box is
going to be the outside skin of the car (aerodynamic shape is very important). I am not sure if the 2 of
4x2’s will make a stiff enough body; stiffness is important to the handling of the car, although a small
amount of
torsional

flexibility helps keep all 4 wheels on the ground in a car with no suspension.


Steering is something that has to be considered with the shape of the body. A steering system that requires
a lot of room to build or to operate can increase the size of the car. Raptor Fusion, the
Penair

Car, uses side
sticks in order to reduce the height of the car.


The weight distribution information is important. An easily handled car will be quicker and cause less driver
fatigue.


Although aerodynamics is important, keeping the weight low is worth doing. It may not make a big
difference, but it does make some difference.


Gearing can help in setting the car up for a particular track, and can help keep the motor running at it’s
most efficient point. Putting a cassette on the motor shaft could be a problem, as it is backwards from how
normal bicycle parts work, and may require a lot of custom work to get right. It also has to be considered
that we have drivers of differing abilities, and a shifting system that is not foolproof stands a good chance
of breaking and putting the car out of the race. To finish first, first you have to finish!



First Idea

Nathaniel Olson GCSE Resistant Materials


This chassis is loosely based on a design from
Penair

School, Their car came 4
th

in the national
championship so I thought it would be a good starting point. This idea uses the space beside
the legs to fit the wheels in. This makes the car thinner and more aerodynamic. The motor sits
underneath the driver’s seat. This is both a good and bad idea. It’s a good, neat place to put
it, but the motor can get very hot while driving and the lack of air flow would burn out the
motor. The batteries are behind the driver as it’s most convenience place to put. It make the
access to it easier because fast pit stops are necessary in order to do well in the race.
Steering is a push and pull system which steers the car. This method is very easy to do and
allows a large degree of turning.


I chose this car because it was






the most practical and most
developed out of my three ideas.

Second Idea

Nathaniel Olson GCSE Resistant Materials


I didn’t get very far with this idea as I struggled to find places to mount the batteries, motor,
wheels, roll bar and steering components.


The idea was a simple wooden box would be mounted to two long timber posts. The cross axle
would be mounted onto the timber posts. The motor and batteries would be mounted on a
partition that hangs from the posts. This idea would end up being too complicated and very
tight spaces which would decrease the efficiency of the motor.


The big disadvantage of this car is that it’s not very aerodynamic which is vitally important in
in
Greenpower

racing. There wasn’t any place to put the body on it . I didn’t choose this idea
because it wasn’t practical and it has a aerodynamic disadvantage.

Third Idea

Nathaniel Olson GCSE Resistant Materials


This is a modification on the previous idea. The box underneath
has been replaced by a Raptor fusion chassis shape. This car
has more support for a aerodynamic body. This would work the
same way as the previous idea, but would have more space
for components.

Final Idea

Nathaniel Olson GCSE Resistant Materials


Complicated Version

Nathaniel Olson GCSE Resistant Materials


After making the basic version of my car, I need to make
the proper version of the car with individual pieces all
mated together to make a functional car. The left picture
shows what my basic idea was turned into and then the
right picture shows the near completed car. In the next
slides I will be showing the progress of the car and how
each element of the car will be made and function.

Slots that builds the car

Nathaniel Olson GCSE Resistant Materials


The each piece of the
car would be have slots
and tabs that can slot
into another piece that
has the matching slots
and form a solid joint.


Top Piece and the Man

Nathaniel Olson GCSE Resistant Materials


The top piece will be added onto the top of car, making the
car stronger and more durable. This is crucial as the car to be
lasting for 4+ years. The top will be attaching itself to all of
the top edges and will have a cut out for the driver to get in
and out.


What happens in a race is that the car travels over 1000
decent size bumps, even on a race track, during the 4 hours of
racing. All of the loose parts in the car such as the body can
amplify the vibration. This vibration needs to be sustained by
the car otherwise it will fall apart after a race or two.


In order for my car to be able to fit a normal human being, I need
one in my car, so I downloaded a man from the internet and inserted
him into my car. Things that I have found out about the car:


The motor layout won’t work


Car is too thin


Car is too long


Batteries and Motor Layout and

The Shape of Chassis

Nathaniel Olson GCSE Resistant Materials


There are several advantages from this layout.


Firstly the heat that the motor is emitting can be direct into the batteries
making them perform better. This can be done by mounting the motor on an
aluminium sheet which would bend over the wall that surrounds the batteries
and into the box.


Secondly, the layout helps the weight distribution to be more central which
then would help the manoeuvrability and difficulty of steering the car.


Thirdly the motor is neatly tucked away under the seat, which gives up space
behind the batteries which then can be used for electrics and the jack shaft
that will drive the wheel.


The shape of the chassis has been design to take advantage of a human body’s shape. As the shoulders are a lot wider then
the hips and legs, I make the space around the legs a lot thinner. This allows space for the wheels to be there and able to
move. This would allow the car to be thinner and have more aerodynamic advantage.

Frontal Support & Wheel Positions

Nathaniel Olson GCSE Resistant Materials


Because my car is a effectively a rectangle that can be swayed side to side to
form a parallelogram. This is bad for the car structure and should never happen.
After building my first model, I thought it needed more support.


So, I created a wooden triangulated brace that attaches to the base and the
sides. The reason for the triangle shape is that it’s a good shape to support the
forces the car can subject to during the race, the hole are there for making it
lighter. This will improve the stability and structure of car.


The wheels positions are important as they determinate the weight distribution and manoeuvrability of the car. The front
wheels are on the edge of the car rather then being inside as they need as much space as possible to rotate to achieve tighte
r
turning circle. This current setup can do a 10 metre turning circle which is more manoeuvrable than a road car.


The back wheels are inboard so the body can go around the wheels and not be interfered by them. This is designed to be
more aerodynamic.

Cross Axles and Roll Bar + Braces

Nathaniel Olson GCSE Resistant Materials


The cross axles and plates are the most important parts of the chassis as the
wheels will be bolted on it. Therefore I needed to make it out of steel as they
are much stronger then wood but much heavier. Fortunately it is a small
component and wouldn’t affect the weight much.


The only logical way that I can think of that allows the cross axle to be
attached securely to the wooden chassis was to weld a steel plate onto the
cross axle. Then I could bolt the whole component to the chassis. This wouldn’t
need much skill to make and it’s easy to do.


The roll bar will be a 1 inch tubing bent in shape and welded to two plates which then
would be bolted through the base of the chassis and another plate underneath to
ensure that the bolts don’t rip through the floor. To ensure that the roll bar will be in the
right position when putted into the car, I have made a jig that you can bolt the plates to
and then weld the tubing to it.


The braces will be welded to the roll bar at one end and the other end of the ¾”
square will be bolted to one of the holes in the axle plate.

Steering Layout and
Drivetrain

Nathaniel Olson GCSE Resistant Materials


This was my first idea for the steering. Using aircraft
style handle you would push and pull to rotate the
wheels. This idea hasn’t been fabricated but is a
suitable one. There would be 3 trackrods, one to keep
the wheels aligned, this would be done by attaching
the two kingposts together. Also there would be one
end of another trackrod attached to the kingpost of the
one wheel and the handle that is on the same side and
would be the same for the other side.


This would be a easy and functional way of doing it.
Also it’s very similar to the
Penryn’s

Greenpower

car
steering layout.


My original idea for the drive train was that to have the motor in front of the
battery box but due to limited space, I had to put the motor behind the battery
box. This has a big effect on the weight distribution which affects the steering and
the manoeuvrability of the car.


So I chose to use a jack shaft to transfer the power from the motor to the wheel.
This is done by a free rolling shaft that has 2 gears on it. The motor will drive the
first gear on it and that will transfer to the second gear on the shaft. That gear
will then drive the wheel. This is shown in the top picture on the right.

Harness Mounting and Electrics

Nathaniel Olson GCSE Resistant Materials


The harness that we are using is a 5 point harness, two above the
shoulder, two next to the hips, one between the legs. This is required
as the rules stated that if the seat is less then 30 degrees which in this
case is less then a 5/6 point harness is needed.


I used the model man to determine the mounting position.


The harness strip will be weaved through 2
flatbar

bolted to the
surface. This makes it very rigid and easy to adjust. The shoulder
harnesses will be bolted from the battery box and the rest will be
bolted to the floor of the car.



The electrics will be mounted near the motor to reduce the amount of
energy lost in transferring the power. Also because the motor will be
cooled from the top, it will also cool down any hot electrics.


The electric will be almost identical to our school’s car which is simple
as it gets, but it will have a motor controller which would a circuit
controlling the solid state relay. The picture below shows the layout of
the electrics


Changed the Steering and Motor Layout

Nathaniel Olson GCSE Resistant Materials


I have changed the motor and drive train layout as I have concluded that my previous
version was too complicated and more liable to break. This has lead to me changing the
drive system from a jack shaft arrangement to a direct drive system.


This arrangement is being used by many cars on the grid and it’s the most simplest way
of doing it. It has one chain running from the motor shaft gear to the big gear on the
wheel. What it does is that the motor has to be move back to allow the chain to be direct
and the motor needed to be moved over.


The advantages of this way is that it’s very unlikely that it will break, it’s also increases
the efficiency of the drive train and allows us to use more power.

Also it will be easier to
cool as isn't pressed against the surface. The disadvantages of this arrangement is that
the weight distribution is not as good as before as the motor has been moved back.


I changed the steering layout as there wasn’t going to be
enough room for all the linkages between the handle and the
wheel.


So I have adopted a system that is similar to Richard Lander
and vaguely to Rotary Racers (No.1 in the country)
. This uses a
handlebar

which is welded to a steering shaft. Further down
the shaft is a plate that is also welded. When you turn the
handlebar, the shaft rotates and moves the plate side to side.
2 arms are bolted to the plate and the ends of each arms will
be attached to the wheels.


This

is a simple, straight
-
forward way of doing the steering.
The sensitivity

of the steering can be adjusted by changing the
height of the steering plate hole.

Refinements

Nathaniel Olson GCSE Resistant Materials


The front section has been tapered narrower so it
allows smaller bodies to be fitted over. It also saves
weight by about 2kgs


Doubler piece is placed where the motor is
mounted. This is to ensure that the motor won’t rip
through the floor and cause the car to have a
failure. This is simply another piece of 12mm
plywood glued and screw to the base.


Body Shape and Exploded View


I made a body to see how it would look like in real life and also
see if there is going to be any problems such as the chassis
poking through the body at certain points.









On the left and below are some pictures showing the exploded
view of the car and how most of the components go together.

Nathaniel Olson GCSE Resistant Materials

Orthographic Drawing

Nathaniel Olson GCSE Resistant Materials

Model Evaluation #1

How will you change your design now that you
have made a model
?

As this is a computer model, I made lots of changes to the
design as I went along. Slide 27


37 shows what I changed
in the model.


What have you learned from making the model?

I have found out numerous things about my initial idea, how some of it
will work and some of it won’t. I learnt that it was going to take longer
than I had expected for me to design the car. Initially I intended to
design for 1 month but in the end it took 3 ½ months to complete a
working model on the computer. All of the changes and development
that I have done are from slide 27 to 37.


What
processes could you use to make the real
thing?

I would use a state of art router to machine all of the pieces with
super accuracy. Then I would use a electric hand drill to do the
rest. Some filing and sanding is also required to make sure
everything fits together.




What materials would you use to make the real thing?

I would use wood and metal screws. There would also be wheels
and metal parts for the steering, roll bar, and wheel components.

12 mm plywood would be used for most of the chassis. All of the
metal parts will be standard carbon steel. Also for the steering shaft
holder will be made out of hardwood. To increase the strength, I am
also using timber for corner blocks.

What finishes would you use to make the real thing?

The steel would have a coat of primer and 2 coats of black on top.
The plywood would need to be waterproof, as if the water soaks into
the plywood, it could warp the car and affect the performance, so I
am using a solvent
-
based paint to cover the wooden chassis.

Computer

Model

Model Evaluation #2

How will you change your design now that you have
made a model
?

The model needs to be developed a lot more to make sure all of
wheels and steering components will fit into the car without
clashing with each other. The joints needs strengthening, so I
am going to put timber blocks in ever corner inside the cockpit
and around the battery box area.


What have you learned from making the model?

I learnt that I needed to make the chassis stronger and less liable to
sway side to side. It needed some braces around the front wheels.
Also the car needs some wood to restrict it from flexing lengthwise.

The overall structure and layout looked good and in proportional with
the human body shape.

The car need to be developed a lot more.

What
processes could you use to make the real
thing?

I would use a state of art router to machine all of the pieces with
super accuracy. Then I would use a electric hand drill to do the
rest. Some filing and sanding is also required to make sure
everything fits together.




What materials would you use to make the real thing?

I would use wood and metal screws. There would also be wheels
and metal parts for the steering, roll bar, and wheel components.

12 mm plywood would be used for most of the chassis. All of the
metal parts will be standard carbon steel. Also for the steering shaft
holder will be made out of hardwood. To increase the strength, I am
also using timber for corner blocks.



What finishes would you use to make the real thing?

The steel would have a coat of primer and 2 coats of black on top.
The plywood would need to be waterproof, as if the water soaks
into the plywood, it could warp the car and affect the
performance.

Simple Card

Model

Plan of Make

Nathaniel Olson GCSE Resistant Materials

Stage

Process

Equipment Needed

Possible Problems

Safety

Checks to carry out

1

After finishing the 3D model of the
car, arrange the parts onto a flat
sheet.

Computer, Solid works.

Concerned about the amount
of space available as I am
hoping it will fit on 2 sheets of
plywood

No safety checks needs

Make sure that the pieces don’t
o癥牬慰 e慣h o瑨e爠慮T⁴ e 物gh琠
scale factor.

2

Use a state of the art CNC Router. to
cut out all of the wooden parts

Computer, CNC Router,
12mm plywood.

There shouldn’t be any
p牯ble浳

䵡步 su牥⁹ u 慲a 慷慹a
晲f洠瑨e慣hine when
ope牡ring.

䵡步 su牥⁴ e w慴a爠橥琠捵t瑥爠rs
p牯g牡浭rT 物gh琮

3

Use a state of the art water jet cutter
to cut out all of the flat metal parts

Computer, Water Jet
Cutter, 3mm sheet metal.

There shouldn’t be any
p牯ble浳

Make sure you are away
from the machine when
operating.

Make sure the water jet cutter is
programmed right.

4

When got all the parts to make the
car, do a dry run to make sure that all
of the pieces fit together seamlessly.

Hands, Parts for the car.

If the pieces don’t fit together
then there is a big problem.

Avoid the sharp edges.

Make sure all of the pieces fit
together.

5

If successful in the dry run, put the
wooden parts together with wood
glue following the instructions below

Clamps, Wood glue.

There shouldn’t be any
problems unless the dry run
didn’t work out.

Avoid the sharp edges.

Make sure all the pieces fit
together in the right order
otherwise it will go wrong very
quickly.

6

The front side pieces needs to be
glued to the middle piece and the two
shaft holder. Use the base holes to
align the pieces while gluing.

Clamps, Wood glue.

There shouldn’t be any
p牯ble浳

A癯iT 瑨e⁳h慲a eTges.

All o映瑨e 橯in瑳⁨慶攠瑯 be 物gh琠
慮gleT.

7

When glueT 瑯ge瑨e爠co浰le瑥l礬 glue
the front component from the last
step to the base piece. Make sure the
base is on the right side.

Clamps, Wood glue

There shouldn’t be any
problems unless the base is
glued the wrong face around

Avoid the sharp edges.

Make sure the base is on the
right side

8

When the last step is done, glue the
bulkhead piece onto the front of the
car.

Clamps, Wood glue.

There shouldn’t be any
p牯ble浳.

A癯iT 瑨e⁳h慲a eTges.

䵡步 su牥⁹ u pu琠i琠tn⁴ e⁲ gh琠
w慹a慲aunT.

Plan of Make 2

Nathaniel Olson GCSE Resistant Materials

Stage

Process

Equipment Needed

Possible Problems

Safety

Checks to carry out

9

Put all of the battery box pieces
together with glue. Use the base holes
to align the pieces while gluing.

Clamps, Wood glue.

There shouldn’t be any
p牯ble浳.

A癯iT 瑨e⁳h慲a eTges.

䵡步 su牥⁹ u pu琠i琠tn⁴ e⁲ gh琠
w慹a慲aunT.



When 瑨e l慳琠t瑥p is⁤one, glue 瑨e
battery box to the base.

Clamps, Wood glue

There shouldn’t be any
problems.

Avoid the sharp edges.

Make sure you put it on the right
way around.

11

After that, glue the middle section
onto the sides of the car.

Clamps, Wood glue

There shouldn’t be any
p牯ble浳.

A癯iT 瑨e⁳h慲a eTges.

䵡步 su牥⁹ u pu琠i琠tn⁴ e⁲ gh琠
w慹a慲aunT.



啳ing 慬a o映瑨e co牮e爠rloc歳
p牥癩vusl礠浡me, glue 慮T sc牥w 瑨e洠
in 慬a⁩ siTe co牮e牳⸠

䍬慭ps,⁗ooT glue,
powe爠T物ll.

There shouldn’t be any
p牯ble浳.

A癯iT 瑨e⁳h慲a eTges 慮T
h慮Ts shoulT be cle慲ao映
whe牥⁹ u 慲a T物lling

䵡步 su牥⁴ 慴⁴ae 物gh琠co牮e爠
bloc欠koes⁩ 瑨e 物gh琠pl慣e.



All o映瑨e wooTwo牫 is 晩fisheT, nex琠is
瑨e b牡ring映瑨e 浥瑡t p慲as.

䉲慺ing⁥quipment

There shouldn’t be any
p牯ble浳 慳 long 瑨e 浥瑡t
pieces 慲a⁣u琠ou琠tigh琮

We慲a晩fep牯o映o癥牡rls 慮T
晡fe m慳歳.

䵡步 su牥⁴ e pieces 慲a 慬agneT
p牯pe牬礠be景牥 b牡ring⁴ e洠
瑯ge瑨e爮



Fi牳瑬礬 瑨e c牯ss 慸les supplieT 瑯⁵s
neeTs 瑯 be cu琠up 瑯⁴ e⁲ gh琠leng瑨⸠
Then e慣h siTe o映瑨e c牯ss 慸leeeTs
瑯 b牡reT⁴ 瑨e 浯un瑩ng pl慴a⸠
Repe慴⁴ais 㐠瑩浥s.

䉲慺ing⁥quipment

There shouldn’t be any
p牯ble浳.

We慲a晩fep牯o映o癥牡rls 慮T
晡fe m慳歳.

䵡步 su牥⁴ e pieces 慲a 慬agneT
p牯pe牬礠be景牥 b牡ring⁴ e洠
瑯ge瑨e爮



S瑥e物ng pl慴a,⁳h慦琬⁨慮Tleb慲a慬a
neeTs 瑯 be b牡reT⁴ ge瑨e爬r慬a
慬agneT p牯pe牬礮

䉲慺ing⁥quipment

There shouldn’t be any
p牯ble浳 unless 瑨e
components weren’t made
p牯pe牬礮

We慲a晩fep牯o映o癥牡rls 慮T
晡fe m慳歳.

䵡步 su牥⁴ e pieces 慲a 慬agneT
p牯pe牬礠be景牥 b牡ring⁴ e洠
瑯ge瑨e爮



䉲慺e 瑯ge瑨e爠瑨e⁢慣欠kheel
慬agn浥n琠pl慴as 瑯ge瑨e爮

䉲慺ing⁥quipment

There shouldn’t be any
p牯ble浳 unless 瑨e
components weren’t made
p牯pe牬礮

We慲a晩fep牯o映o癥牡rls 慮T
晡fe m慳歳.

䵡步 su牥⁴ e pieces 慲a 慬agneT
p牯pe牬礠be景牥 b牡ring⁴ e洠
瑯ge瑨e爮

Plan of Make 3

Nathaniel Olson GCSE Resistant Materials

Stage

Process

Equipment Needed

Possible Problems

Safety

Checks to carry out

17

Braze together the kingpost parts to
form a kingpost. Repeat 4 times.

At the end, grind off a section off the
steering column so the gear can be
mounted on without contact.

Brazing equipment

There shouldn’t be any
p牯ble浳 unless 瑨e
components weren’t made
p牯pe牬礮

We慲a晩fep牯o映o癥牡rls
慮T⁦ ce 浡獫s.

䵡步 su牥⁴ e pieces 慲a 慬agneT
p牯pe牬礠be景牥 b牡ring⁴ e洠
瑯ge瑨e爮



Bend a 1” tube in to a roll bar. Then
welT 愠浥瑡t⁰l慴a 瑯 e慣h⁥nT o映
瑵be.

䉲慺ing⁥quip浥nt

There shouldn’t be any
p牯ble浳 unless 瑨e
components weren’t made
p牯pe牬礮

We慲a晩fep牯o映o癥牡rls
慮T⁦ ce 浡獫s.

䵡步 su牥⁴ e pieces 慲a 慬agneT
p牯pe牬礠be景牥 b牡ring⁴ e洠
瑯ge瑨e爮



A晴f爠慬a⁴ e b牡ring h慳⁢een
co浰le瑥T, 瑩浥 瑯 pu琠i琠慬l 瑯ge瑨e爠
wi瑨u瑳 慮T⁢ol瑳

Hex 祳, Nu瑳⁡ T bol瑳,†

There shouldn’t be any
p牯ble浳 unless 瑨e
components weren’t made
p牯pe牬礮

No s慦整礠yhec歳eeTs

䵡步 su牥⁴ e pieces 慲a whe牥
瑨e礠慲a⁳upposeT 瑯 be.



SliTe e慣h c牯ss 慸le⁩ 瑨ei爠hole 慮T
in瑯 瑨e⁳lee癥s which⁴ en neeTs 瑯
be 瑩gh瑥neT⸠

Hex 祳, Nu瑳⁡ T bol瑳,†

There shouldn’t be any
p牯ble浳 unless 瑨e
components weren’t made
p牯pe牬礮

No s慦整礠yhec歳eeTs

䵡步 su牥⁴ e pieces 慲a whe牥
瑨e礠慲a⁳upposeT 瑯 be.

Instruction Manual

Nathaniel Olson GCSE Resistant Materials


As this is a kit car that
can be sold in the
shops, it would need a
instruction manual of
how to build the car.
So I created one
specifically for this
car.

Working Diary
-

Router

Nathaniel Olson GCSE Resistant Materials

I needed to cut all of the parts out. I
founded a place in Falmouth that can cut
a full sheet of plywood for a reasonable
price.


The process only took about 1 and a half
hours which was quite surprising.


The pictures on the right shows the process
taking place and the components
involved.


This router uses a vacuum pump to suck
the pieces to the base and secure them.

The pictures shows the pieces being cut
out. The process was that it would cut 6
mil into the wood and when it has done
that for all of the lines, it would then go
down another 6 mil to complete the
process.


The parts that are being cut out on the
right are the 2 middle sections, bulkhead
and 1 side piece.


Working Diary


Water Jet Cutter

Nathaniel Olson GCSE Resistant Materials

The same company also does
water jet cutting, which involves
shooting very high pressured
water out of the nozzle and
cutting the material.


This process was used to cut
most of my metal parts such as
gears, cross axles plates,
harness plates, motor backing
plate, roll bar plates and so on.


The process was fairly quick,
about 1 hour to produce 20 or
more pieces.


Working Diary
-

Sand & Filing and Pieces slotted together.

Nathaniel Olson GCSE Resistant Materials

Nathaniel Olson GCSE Resistant Materials

The pictures on this slide show all
the pieces slotted together except
the top piece which would be
fitted to the car after the gluing
and screwing is complete because
the wood may warp and there is
other components to be fitted to
the car beforehand.


In order for the all the pieces to fit together firmly, I
designed all the pieces to the millimetre. When putting all
the pieces together, it became apparent that the slots
would go together in a perfect world without any
expansion or warping of the wood. This meant that I had
to sand down some slots and holes to ensure all of the
pieces fit together correctly.


This process took about a week to complete.

Working Diary


Corner Blocks

Nathaniel Olson GCSE Resistant Materials

Knowing the car now slots together, I got
on with the gluing and screwing the car
together. I used corner blocks to improve
the structural strength of the car. Using the
band saw with supervision, I cut 6 pieces
of 25mm square that are 2.4 metres long.


Working Diary


Glued and Screwed
& Painting

Nathaniel Olson GCSE Resistant Materials


After doing most the of corner blocks, the actual shape of the car to
beginning to appear. The glue is performing well and the whole
chassis is bonded together firmly.


The only concern is that the way that the glue works, it reacts with
moisture and therefore it foams out of the joints. This can cause trouble
because the foam set off quickly and becomes a really tough
substance. When this happened a couple of times during the build, I
would have to get a sharp chisel and try chisel all of the hard foam
off the surface.


After all of the wood work was done except the top piece, I got on
with the painting of the car as it needed to be waterproof otherwise
it will warp and affect the car’s performance in wet weather.


I used a solvent based garage floor paint because it’s a tough,
waterproof paint that will hopefully last for a reasonably long time.
All of the surfaces needed to be painted with 2 coat to make sure no
water will go into the wood.


I painted the top piece and the chassis separately because it’s easier
to paint the inside of the car without the top.

Working Diary


Top Piece, and More Painting

Nathaniel Olson GCSE Resistant Materials


After all of the surfaces
on the chassis and top
pieces were painted, I
glued and screwed the
top onto the chassis using
the same method as
before. After some
finishing touches with the
paint, the wooden part
of the chassis is finished!

Working Dairy


Metal Work

Nathaniel Olson GCSE Resistant Materials


Next I needed to make all of my metal pieces which are very critical
to the functionality of the car. Firstly I began making the cross axles
parts which would hold the kingposts and the wheels. I had to cut up
the cross axle in to the correct length as they were too long. Then I had
to prepare the plates that will be welded to the cross axle as on their
own, there is no way the axle can be attached to the car securely. The
cross axle were designed to be welded on a tricycle.


After the plates were prepped with a light filing and was welded to
the cross axles, I moved on to the kingposts. They didn’t need much
modifications as we designed the car around it. The tabs that controls
the steering wasn’t needed on the front kingposts as it would be
moved. I chopped them off with an angle grinder with supervision. The
back kingposts needed the tab but because the tab was flipped
upside down, I heated the brass weld up and twisted the kingpost
around while the tab was in the vice.

After that was completed, the
2 tubes that will clamp the 4
cross axles together needed
to be made.

A 1 5/8 inch tubing was cut
down into two pieces, 300mm
long and 280 long. A long
slot was cut away at each
end of each clamp tube.

Working Dairy


Metal Work 2

Nathaniel Olson GCSE Resistant Materials


After making all of the wheel components, I
moved onto the
rollbar
. The materials were a
1” inch steel tube and some pieces from
earlier on from the
waterjet

cutter. Firstly I
used a tube bender to bend the tube as
shown on the left. This process took a short 5
minutes to complete. Then I welded the
mounting plates onto each end of the tube
so the roll bar can be firmly secured to the
chassis.


Then I had to do the steering component
which includes several 7/8” steel tubes
welded to together. To make sure they fit
together properly, I used a pattern software
that allows me to cut out all of the joints
perfectly so the handlebar can be perfectly
perpendicular to the steering shaft.

Working Diary


Metal Painting

Nathaniel Olson GCSE Resistant Materials


After all of the metal was completed, I
painted the parts as I don’t want them to
rust due to the horrible weather conditions
during a wet race. A coat of grey primer
was applied to the surface of the metal,
followed by 2 coats of high gloss black.

Working Diary


Bolting the Parts Together

Nathaniel Olson GCSE Resistant Materials


After all of the metal parts were completed, I simply bolted them on with
nuts and bolts. All wheels were attached within 2 hours which is good as I
wanted to be easy enough for little kids to put it together because most cars
at the moment have the chassis welded together and this requires skill and
time that the student don’t have.


The top picture shows the 2 batteries and the motor in the car because I
wanted to test the strength of the chassis with the majority of the parts and
myself in it. I am pleased to say that it’s a rock solid chassis that doesn’t flex
or crack. This means that the chassis is suitable for racing even on bumpy
road surfaces.

Roll Bar


Socket Button M8 30mm (X6)


Nylock

Nut M8 (X6)


M8 Washer (X6)


Harness Mounts


Socket Button M8 45mm (X10)


Nylock

Nut M8 (X10)


M8 Washer (X10)


Cross Axle Plates


Socket Button M8 30mm (X10)


Nylock

Nut M8 (X10)


M8 Washer (X10)



Motor Gear


Grub Screw M12 16mm (X2)


Total


Socket Button M8 30mm (X16)


Socket Button M8 45mm (X12)


Socket Cap M8 20mm (X2)


Grub Screw M12 16mm (X2)


Socket Cap M8 50mm (X4)


Nylock

Nut M8 (X34)


M8 Washer (X36)


Roll Bar Brace


Socket Button M8 45mm (X2)


Nylock

Nut M8 (X2)


Washer?


B
-
Wheel Alignment


Socket Cap M8 20mm (X2)


NylockNut

M8 (X2)


M8 Washer (X4)


Motor


Socket Cap M8 50mm?? (X4)


Nylock

Nut M8 (X4)


Washer?


Comparing the Kit Car with our Old Car

Nathaniel Olson GCSE Resistant Materials


Our school already have a Green
power car that is reasonably
competitive. I used this as a base for
designing my car. I wanted it to be
shallower, thinner in order to have less
frontal area and as you can see in
the pictures that it is.

Kit Car Manufacturing Specification

Manufacturing in School


Materials: Plywood and plain carbon
steel


Sizes: 2 Sheets of 12mm plywood


Weight: 25kg


Printing Method: A Router that can do full
sheets.


Manufacturing Processes: Sand paper,
square files, electric drills, Router.


Finishes/Assembly: Solvent
-
based paint,
polyurethane glue



Manufacturing in Industry


Materials: Plywood and plain carbon
steel


Sizes: 2 Sheets of 12mm plywood


Weight: 25kg


Printing Method: A Router that can do full
sheets.


Manufacturing Processes: Sand paper,
square files, electric drills, Router.


Finishes/Assembly: Solvent
-
based paint,
polyurethane glue


Nathaniel Olson GCSE Resistant Materials

The manufacturing specification for school is the same
as the specification in industry because it can’t be
made any other way.

Problems that I have encountered
during the build of my car

Nathaniel Olson GCSE Resistant Materials


I have discovered that I have forgot to make holes for 3 tabs on the
car. It was two tabs on the bottom of the back bulkhead and a slot
for the back of right hand side of the battery box. This doesn’t
compromise the car very much in its structural strength. But it does
affect the shape and warping of the wood which can cause
problems when fitting and gluing the pieces together.


One after school session that I have attended, I manage to screw
and glued the battery box into the base. The following morning, I
came in to check on if the glue was successful. What I came to
discover was that the back bulkhead has warped itself as said in the
previous point. This meant that one side fitted on perfectly, but the
other side has somehow moved by 3mm. This didn’t do me any
favour as I then had to make the hole bigger so the slot can go in.

Evaluation 1

Nathaniel Olson GCSE Resistant Materials


What did you plan to make?


I planned to make a
Greenpower

kit car that can be supplied to schools that are wanting to compete in
Greenpower

Races. It had to be simple to make and environmentally friendly. It also had to be reasonably
competitive at the national final, achieving a top 15 place. Therefore it also needed to have the ability to
put a aerodynamic body onto it and it also needed to be light.


What did you actually make?


I made exactly what I planned to make. It’s light, small and environmentally friendly. It is also durable as it
should last for half of a decade of racing.


What are the differences?


It isn’t as sustainable as I hope it would be as I have used a solvent
-
based paint which renders the most of
the car useless for recycling, but however by using a tough, durable paint, the car shouldn’t need to be
repaired or replaced which means it doesn’t use up anymore of the environment after it has been made.


Name 3 positive things about the design?


It’s a very safe, light and strong design as it has support on all 4 sides (base, left side, right side and the
top). This contributes to the lightness of the car which is about 25 kg without batteries and motor.



What improvements would make the product better?


One thing that struck me was that the car was wider than expected. This can affect the performance of the
car as it increases the frontal area of the car. If I was to redesign the car again, I would make the chassis
50mm narrower. This has big consequences on the structure of the chassis as it will intersect with the wheels.

Evaluation 2

Nathaniel Olson GCSE Resistant Materials


How does the product meet the specification?


Must fit the regulations set by
Greenpower
.


The entire kit car fully complies with the rules.


Be able to fit wide range of people into it.


It can fit a person that can be from 4ft5” to 6ft5”


To be built largely from wood or other sustainable/recyclable materials.


It is made from recycled metal and sustainable plywood.


To be designed to take advantage of modern computer controlled manufacturing techniques such CNC routing and
waterjet

cutting. This
will reduce costs, increase manufacturing accuracy, and keep material waste to a minimum.


It uses a state
-
of
-
the
-
art CNC router to manufacture all the wooden pieces and a
waterjet

cutter for the metal parts.


Will be easily modified by student clubs to their preferences.


As it’s made out of wood, it can be cut up and modified easily.


Have the ability to put a aerodynamic body over it


The shape of the chassis allows a very aerodynamic body to go over it.


Be easily repaired after a crash


As it’s made out of wood, it’s easy to attach new parts and pieces on it.


To provide instructions/documentation that show how the car is assembled, and the design principles behind the car. This all
ows

the
school to use the
Greenpower

car as part of the curriculum.


The instruction manual can be seen on slide 44.



Evaluation

Nathaniel Olson GCSE Resistant Materials


How have you tested the product? Was this a suitable test?


I have asked students and staff about my car and what they think of it. I have received good feedback saying the car is very
good overall. Students have been climbing into the car, trying some features of the car and getting a feel for it, all studen
ts
felt that the car was big enough for themselves and had no trouble with it. When I showed it to other students in the school,

my

car wasn’t completed as I didn’t have the roll bar and the steering in it. A more suitable test would be have the whole car
done, give it to the students and they drive it around and they tell me their feedbacks.


Can you suggest 2 improvements as a result of the testing?


Make the car narrower and shallower as they felt there was too much room in the cockpit. The steering system need to be
changed as they would preferred side sticks to a handlebar.


How did you use the research?


I used my research to determine what was needed for my car and what it didn’t need. For example, I did some research on
Raptor Fusion which came 4
th

in the National Final, the overall shape of it uses the space in the car efficiently and I have
incorporated that in my design as you can see in my development on slide 30.


What extra research could you have used to improve your design?


I could’ve done some research on weight distribution and on how that affects the steering geometry and the feel of it as I ha
ve

absolutely no idea on how sensitive it will be. This can affect the rolling resistance of the car around the track.


Have you investigated environmental, ethical, social, and cultural impacts of the product?


This can be seen on slide 4.


How have you evaluated your work throughout the project?


I have had several opinions about my design from other teams and schools and how to improve it. I have made a couple of
models to test certain things that was concerned about such as I need to test the structural integrity of the chassis, so I m
ade

a
card model to see how stiff it was. In my computer model, I need to see whether a person would fit inside the car so I
downloaded an
ergonome

off the internet and used him to evaluated my model and see if it works.