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Rotary Racer 9: Todo List 2012 - 2013

Things todo

Status	Work	Who
Done	Ideas for new car, research and discussions	All
Done	Cars overall body design 3D CAD with VWT testing	GB,DD
Done	Cars 2D chassis plan/side drawings for component placement and paper building plans	GB
Done	Searching for materials and component suplliers	TA,PL,RL,KA,TB
Working	Ordering bits	KA,TB,PL
Done	Complete tube frame	All
Done	Add side impact bars	ML,JL,RL,PL,LB
Donw	Add traingle stiffening to frame
Done	Rollbar/rear axle design 3D CAD.	GB
Working	Make roll-bar/backaxle assembly
Done	Fit rollbar/back axle	GB,DD,DB,LB,TB
Done	Lathe rear subaxles from aluminium	JL,DD,MD
Done	Steering 3D/2D design	GB,TB,DD,MD
Done	Make steering components with lathe	All
Done	Design disk brake holders	GB
Done	Fit disk brake holders	GB,TB
Done	Make adjustable steering column (Used old one so take from old car)?	BS,LB
Done	Fit steering arms	GB,TB
Done	Fit adjustable steering column	ML,JL,PL
Done	Fit back axle/roll-bar	GB,DD,DB,LB,TB
Done	Design seat	LB,SD,MD
Done	Make seat	LB,SD
Done	Fit seat and harness	ML,JL,RL
Done	Design motor mount	GB
Done	Make motor mounts	GB
Done	Fit motor	GB,TB
Done	Make wheel gear spacer aluminium (Use one from old car)
Done	Design battery mounts and fit	TA,KA
Done	Fit electrics and electronics	LB,ML,JL,PL,TB
Done	Cut and fit plywood bottom and top. Carbon fibre re-enforce	ML,JL,RL,PL
Done	Fit internal foam	DB,SD
Done	Cut and fit foam sides and other aerodynamic shapes	All
Done	Make and fit nose cone	ML,JL,LB,MD
Done	Make and fit rear tail	GB
Done	Control systems	DD,TB
Done	Communications equipment research	TA,KA
Done	Test the car	All

Things to design/decide:

Motor mount
Hinged bonnet and electronics dashboard.
Power control system manual/automatic and controls
Battery mounts and connections

Ideas for new car:

Ideas.html

Date	Description
22/10/2011	New season meeting on what to do. Create list of materials to purchase. Create lists of tests to do. GANT chart.
4/11/2011	Need to check position of tubes (especially seat) of new car wrt RR8. Check the height of the car is Ok for drivers to get in. Measure diameter of wheels with Kojak tyres on. Order bits. Final and rears writeup complete and send into school. Send to papers etc ? Add paper sheet about win to notice board Website diary system. Add entry. Design steering. Design rollbar/back axle. Search internet for smaller 6 point harness. Get 2D CAD plans for RR9 ready Misc Could do's. Take a video of stripping down RR8's old motor.
12/11/2012	2D CAD plans for RR9 are ready and printed. Start bending main tubes for chassis. Cut out main side to side and top to bottom tubes. Insert bungs Send in final writeup to school. Update RR's notice board. Research and choose harness. Steering design Rollbar/backaxle design. Order bits. Website diary system. Add entry.
19/11/2012	Bend main tubes to shape Cut out main side to side and top to bottom tubes and insert bungs Choose harness. Order plywood and carbon fibre cloth Steering design 3D or 2D CAD Rollbar/backaxle design 3D or 2D CAD Website diary system. Add entry. Update RR's notice board. Motor mount ?
26/11/2012	Insert self tappers into bungs Bend main tubes to shape Choose harness. Order plywood and carbon fibre cloth Steering design 3D or 2D CAD Rollbar/backaxle design 3D or 2D CAD Website diary system. Add entry. Update RR's notice board. Motor mount ?
10/12/2012	Ideas for RAF Check bung angles Bolt frame together Steering design 3D or 2D CAD, Check sizes Rollbar/backaxle design 3D or 2D CAD, Check sizes Cut tubes for rollbar and steering Make steering kingpin ends with lathe Order plywood and carbon fibre cloth Website diary system. Add entry. Update RR's notice board. Motor mount , how to do this?
7/1/2013	Short meeting: Where we are at ? Ideas for RAF Bolt frame together Rollbar/backaxle design 3D or 2D CAD, Check sizes Cut tubes for rollbar and steering Continue making steering kingpin ends with lathe Order plywood and carbon fibre cloth Website diary system. Add entry. Motor mount , how to do this? Which races
14/1/13	Fasten fron and rear bits to frame Make side impact bars Make and corner stiffening trangles Rollbar/backaxle design 3D or 2D CAD, Check sizes Cut tubes for rollbar and steering Continue making steering kingpin ends with lathe Website diary system. Add entry. Motor mount , how to do this? Which races
21/1/13	Finish frame. Rollbar/backaxle design 3D or 2D CAD, Check sizes Continue making steering kingpin ends with lathe 'C' programming Website diary system. Add entry. Motor mount ,
28/1/13	Make seat tubes and loosly fit to frame (position to be decided. Fit corner stiffening trangles Bend rollbar Cut rollbar cross members and axle Cut tubes for steering Continue making steering kingpin ends with lathe/milling machine Seat plans/patern design 'C'/'C++' programming for simulator Website diary system. Add entry. Motor mount , how to do this? Which races (Dunsfold or Merryfield)
4/2/13	Re-make seat tubes and loosly fit to frame (position to be decided). Fit corner stiffening trangles Bend second part of rollbar Cut rollbar cross members and axle Cut tubes for steering Continue making steering kingpin ends with lathe/milling machine 'C'/'C++' programming for simulator Website diary system. Add entry. Motor mount , how to do this?
25/2/2013	Start sewing the seat. Fit corner stiffening trangles Bend second part of rollbar Cut rollbar cross members and axle Decide on how to mount ollbar cross members and axle (brackets ?) Start welding roll-bar Cut tubes for steering 'C'/'C++' programming for simulator Cogs and chain purchase Research and look at purchasing communications. Research and look at purchasing marque.. Website diary system. Add entry. Motor mount , how to do this? Funding ?
4/3/2013	Continue sewing the seat. Cut rear axle Start welding roll-bar Cut tubes for steering 'C'/'C++' programming for simulator Research and look at purchasing communications. Research and look at purchasing marque.. Website diary system. Add entry. Motor mount , how to do this? Funding ?
8/4/2013	Fit rollbar to car: Bolt cross members in and weld rollbar to them. Weld rear axle to rollbar Make aluminium stub axles (Lathe) Bolt steering uprights tubes to car Make balljoint threaded inserts on lathe Design disk brake mounting plates Make disk brake mounting plates
15/4/2013	Fit aluminium stub axles to the rear axle Drill steering uprights tubes for balljoint inserts and weld inserts in Fit kingpin to steering uprights using ball joints Caclulate ackerman angle for steering arms Make and fit steering arms Make disk brake holding plates with threaded inserts Drill and tap motor sprokets (6mm)
22/4/2013	Modify steering stubs to 18degree angle. Weld steering stubs to kingpins. Make caliper mounting stubs and weld in place. Make steering upright insers (next 2) and fit all 4. Make steering arms. Drill and tap real axle stubs to correct depth. Cut out bottom plywood (make sure will fit tight against the wheels. Caclulate ackerman angle for steering arms. Remove steering joystick from old car Remove motor from Old car Drill and tap motor sprokets (6mm) Make up steering tie rods (8mm threaded steel)
	Drill our rear sprocket to match spacer Fit seat Fit Seering joystick
29/4/2013	Weld kinpin boss. Drill and tap kingpin boss for axle at 18 degrees Weld capliper brake plate to kingpin Finish kingpin mounting threaded inserts Drill holes in steering members for rose joints Replace rollbar cross member at right height! Make motor mount bits Fit harness Work our ackerman angle Cut and shape steering arms Cut out top and bottom plywood Design battery mounts Remove electronics from old car Design electronics mounting aluminium and cut out and start to shape
	Weld motor mount bits to car Weld steering members for rose joint bosses in steering member Fit motor to car
6/5/2013	Fit battery mounts to car Fit bottom plywood
13/5/2013	Finish welding, weld steering arms Clean up steelwork for painting. Cut bottom ply to fit Cut out bonet plywood Cut and fold Electronics rear box Make circuit breaker mounting plate. Make Power switch mounting braket. Cut inner 1.5mm plywood (by wheels) Work out driver side protection panels required Make nose cone
17/5/2013	Fit rear rollbar assembly to chassis Fit steering assembly to chassis Make steering tie rods and fit. Fit wheels Fit motor Fit brake lever and throttle
20/5/2013	Carbon fibre re-enforce plywood bottom Fit inside plywood panels (1mm plywood) Start fitting electrics Fit drive chain Fit aluminium sides Make and fit rear rollbar strut Make hinged bonnet (method of holding shut) Cut value holes in wheel outsides.
21/5/2013	Make battery box 4mm plywood (How do we hold batteries in ?) Fit display panel and switches Fit electronics Fit wiring Fit aerial and GPS Fit horn Cutout foam panels Glue foam side pieces together reduce size of foam in battery boxes to 30mm
27/5/2013	Half term Fit and shape foam sides Shape nose cone Fit driver side foam Catch up !
3/6/2013	Make and fit steering limiter Design and fit battery box Fit electronics box and begin wiring. Make rear plywood top panels. Add more rivets to side panels. Fit driver side foam Check walkie talkies Catch up !
6/6/2013	Strngthen foam with epoxy in front wheel arches Mirrors and control panel Battery box fit Battery hatches fit Wiring more Paint car
8/6/2013	Final electrics/electronics Tracking Adjust seat. Check things Catch up ! Test car works! Packup for Goodwood
9/6/2013	Goodwood
10/6/2013	Post race meeting and action plan. Rotary Club visit
18/6/2013	Wind tunnel experiments Make temporary rollbar aerofoil fairing Look at battery cover design and improve Make behind head fairing Make new behind head foam. Make rear wheel covers Reshape rear end Improve seatbelt mountings Look at communications: (New pitboard with communications, radios etc) Look at new driver information display and switches. Shape distance, position (close to driver at the moment) etc Improve around driver area with plywood, foam and improved windshield Look at disk brake calipers and free up (use old calipers ??) Electronics protection plate Add electronics laptop connection jack Allow battery number to be changed while driving.
24/6/2013	Design new LED brake light in tail
2/6/2013	Make new LED brake light in tail
Future	Wind tunnel experiments Improve tail mounting Make real rollbar aerofoil fairing Test telemetry range Shape behind front wheels Look at nose shape Remake tail Order and replace all wheel bearings Order spare lyres and tubes Look at speed controller efficiency. New, improved speed controller ? Improve battery connections (shorter, thinner cable to vertical battery connectors or spacial battery connection plates ?) Softer rear (suspension ?) Improve speed control algorithms with Dan's code Increase horn loudness Pitstop practice Proper bonnet hinge and look at hold down system (velcro/magnets) Check for sharp bits (battery compartment)
8/7/2013	Rockingham Test RR9 in wind tunnel
16/7/2013	Test improve behind head sections Test RR9 in wind tunnel Improve behind head Add foot bars Add bonnet cross stiffener Improve windsheild Setup speed controller test platform Look at improved display/control buttons Look at improved tail Speed up/down board imrovements Walkie talkie improvements Fix old motor
22/7/2013	VWT tests of nose and tail heights Order new tyres Make improved behind head bits Make improved tail Sand down all of car for re-paint Speed controller tests Fit new bearings for test
Holidays	Speed controller tests
2/9/2013
9/9/2013	Sand down all of car for smooth re-paint Final repaint of car
14/9/2013	Merryfield
16/9/2013	Fix computer display Remove hinge sharp bits Re-do battery wires if possible. Replace some wheel bearings ? Pitstop practice Behind head foam Telemetry Speed controller efficiency Start on new tail foam Replace tyres after Merryfield
19/9/2013	Fit new wheel bearings Fit 3 new tyres Check and refit speed controller Change gears Fit new telemetry areial and change frequencies used Cycle new batteries 2 times Shape and fit new windsheild Re-program software Repaint bits Fit RAF logos
22/9/2013	Castle Coombe
30/9/2013	Post race meeting Pitstop practice Start on new tail New battery wires. Update display board for open evening Make rear wheel covers, vacuum forming.
7/10/2013	Shape the rear tail (power plane, sanding) Shape the behind head foam area (power plane, sanding) Cut battery door levers down in length and shave off edge of LH door. Add screw to LH lower side just in front of rear wheel. Change gear to 20 tooth. Make up barke lights and rout groves and glue. Try out behind helmet fitting. Cut foam for behind helmit fitting. Take off stickets and sand down car body ready for painting. Pitstop board numbers. Fit new tyres Need to buy some medium helmets (ideally similarly shaped at the rear to current small ones) Improve microphone mounting and cables. (Need some soft foam/velcro) Pitstop practice
9/10/2013	Paint car Fit new battery leads
11/10/2013	Fit stickers Label batteries Check tracking Replace tyres
13/10/2013	Goodwood final (We won :) )
	Future bits