December's Work

Following the tear down in November, the team began work on the improvements to the car. A new array, lighter suspension and electronics, and lots of composites work to the lower body are just some of the tasks that are underway.

The mold for the array had some final repairs to the surface repaired and then waxing got underway. After many of the newer members helped with the waxing, an initial layer of surface coat resin was laid. This is the layer that will give the Sunseeker a smooth outer surface. During finals week, Mitch, Nick, and myself returned to the lab for one last time in the semester to lay the first layer of fiberglass. We began by preparing all of the materials we would need. Vacuum bag, breather cloth, peel ply and the fiberglass were all cut and weighed. While preparing the last of the materials, a second layer of surface coat was laid to give us a layer of resin to lay the fabric into.

Once the resin began to tack, we quickly went to work. Two of us would hold the fabric above the surface while the third laid it onto the surface so that there were no bubbles or wrinkles in the fabric. This was no easy task because the fabric refused to slide once laid into the thick surface coat resin. After a piece of fabric was in the mold we spread a layer of laminating resin onto the fabric to completely wet it out. Eventually we got a strategy down and the fabric rapidly covered the mold. As I laid and soaked the last of the fabric in the canopy (because the other two couldn't reach that area), Nick and Mitch grabbed the peel ply and began to lay it into the mold. We then added the breather and vacuum bag. A few minutes later, the job was done and the part was under a solid vacuum.

The electronics have all but disappeared to the electrical labs on the far end of the building. Testing and optimizing of the electrical system are the primary goals of the electrical team. The suspension is also going through some optimization. When the rebuild comes around the vehicle will be much lighter and more efficient.

The lower body is getting its fair share of attention this winter as well. Some under body sanding was carried out to smooth out the rough spots that were never repaired after the damage caused by removing the part from the mold last spring. We are also planning out an air intake system for the battery, sealed wheel wells, and a stronger, lighter interior structure.

The team will be back to work the Sunday before classes start this spring. Keep an eye on this blog, because the updates will be weekly and full of exciting information and news!

Bronco Pride,
Joshua