As January Closes...

Tonight we laid yet another layer of fiberglass into the array. Here is a list of the layers from the exterior surface to the interior: surface coat resin, one layer of fiberglass, a layer of carbon fiber, quarter inch thick layer of Nomex honeycomb, and two more layers of fiberglass. We may still add another layer of fabric for added support before adding structural ribs to the interior surface.

Progress on the lower shell repair is coming along quickly. Team members spent several hours tonight sanding the added material and adding more body filler to the area in preparation for repainting.

Bronco Pride,
Joshua

The Work Continues

In the past week, the team has continued to make progress on different aspects of the car. The team laid Nomex honeycomb into the part earlier in the week, and then at our Wednesday night meeting we laid a layer of fiberglass over the Nomex. The Nomex layer adds thickness and strength to the part. We will add several more layers of fabric before adding ribs and cutting the canopy section.

The lower body was flipped upside down so that we can work on the lower surface. It was still in poor condition from last spring when it was damaged during the process of removing it from the mold. After a quick sand and grind to bring down any high spots, we added a filler material to the surface and allowed it to cure. Once cured we sanded the surface smooth and luckily for us, the result was much better than expected. It should only take one or two more fill-and-sand cycles before a slick, smooth surface is achieved. Once we reach that point, paint will be applied and the car will be turned back upright so work on the interior can continue.

Bronco Pride,
Joshua

Halfway on the new array

The new semester has begun, and the team is already working hard. This past Sunday, the team laid a layer of carbon fiber into the array mold. This is the second layer of fabric on the part and soon we will add nomex honeycomb followed by several more layers of fiberglass. The plan is to have the final layers of fabric laid into the mold by the end of next week so we can begin to work on the reinforcing ribs and the cuts that will define the canopy section of the array.

The front end of the car is going to see several major fabrication projects. The first is the removal of several Plascore panels around the front suspension mounting area so that they can be replaced with new pieces to allow for a smooth installation of the new suspension system that some of the senior members are busy designing. The battery compartment is also going to see some improvements with a new ventilation system that will improve the amount of airflow to keep the battery pack within operating temperatures.

Bronco Pride,
Joshua Allen