Rotary Racer 10: Todo List 2015 - now

1. VWT: Test raising or lowing front edge of nose code to defect air above or below the car.  (TP)
2. VWT: Test adding front wheel covers to enclose the front wheels using 3D CAD and VWT. (JM)
3. Measure cars dimensions and create a simple 2D cad drawing from top and side. Could use RR9's CAD design and update.
4. Calculate appoximate forwards/backwards centre of gravity if we place the batteries near the front. Test by doing this with our car and scales. (LB, BS, W).
5. Play with car design placing things on full sized paper model.

1. VWT: Testing continues
2. Build new display PCB
3. Make up parts list to buy things for building.
4. Search for items to buy on the Internet.
5. Get list of event dates and times and distribute.
6. Python programming.

1. Finish making 4 x threaded stering support inserts.
2. Check it batteries will fit where we want them.
3. Rollbar: cut and shape cross tube.
4. Rollbar. Cut and shape to join.
5. Subframes: drill 6mm holes in all 8 support brackets.
6. Steering: Cut and shape brake mounting plates.
7. Steering: Cut and shape steering arms.
8. Start welding brakets in place.

Done prior to 2017 winter

1. Order: 4mm Plywood and 1.6mm plywood.
2. Order: New batteries
3. Subframes: weld brackets to subframes (steering and rollbar).
4. Rollbar: weld parts together.
5. Subframes: fit to car.

1. Rollbar:  weld to cross subframe members.
2. Steering: measure, drill and fit/weld balljoint bushes.
3. Brakes: mount caliper plate and caliper mounting stubs (weld). The caliper needs to be aligned with the brake disk with 2mm clearance.
4. Joystick: we have main joystick inner with handle and milled grove.
5. Joystick: cut outer tube to length.
6. Joystrick: cut steering arm from aluminium flat bar (have we some material ?).
7. Joystrick: cut lower mounting plate from aluminium flat bar (have we some material ?).
8. Budget
9. Order brake lever

1. Order: Rear cog and chain.
2. Order: Brake lever.
3. Order: Harness.
4. Order: Joystick clamp.
5. Make: Joystick clamp spacer.

1. Fit steering joystick and ensure clamp tightens correctly.
2. Continue making wheel supports and steering arms.

1. Order: 1mm aluminium sheet (Supplied by Ken)
2. Order: cogs and chain.(Ordered by Terry from Lakehurst Ltd - http://www.lakehurstpt.co.uk)
3. RearAxle: make wheel stubs from 25.4mm aluminium bar on lathe.
4. RearAxle: cut to length and weld to rollbar/subframe at correct height.
5. Joystick: Get setting arm bar welded to tube and grove bolt boss.
6. Joystick: make clamp.
7. Joystick: putchase different brake lever (in line cables). (Purchased from Greenpower website)
8. Joystick: fit (needs 2 x brackets made).

1. Order: epoxy resin for Carbon fibre (Ordered from Rest Express - www.restexpress.co.uk)
2. Steering: fit disks to wheels (3 x washers ?)
3. Steering: weld brake plates and steering arms to kingpin. Need to have wheels and disks in place.
4. Steering: fit kingpins to subframe uprights with 8mm ball joints (two washers each kingpin ?).
5. Joystick: make tie rods and fit.
6. Wheels make plywood panels and fit.

1. Wheels fit tyres.
2. Wheels: fit wheels to car and test.
3. Laser cut out plywood wheel covers

1. Team meeting
2. Weld front kingpins (again).
3. Weld front struts at ends.
4. Fit front king pins. (Do we have suitable spaces/washers and 8mm bolts with nylock nuts ?)
5. Cut and fit steering tie bars.
6. Fit old tyres to wheels
7. Fit wheels acne check if it rolls
8. Laser cut out plywood inside wheel covers
9. Cut out plywood strips for wheel covers 20mm wide.

If there is time:

• Cut Aluminum sides out.

1. Glue wheel covers to make cones. Will need epoxy glue (10min), 2 x clamps, thin plastic sheet, strips of plywood.
2. Purchase get bolts 10mm x 50mm long for king pins.
3. Get bolts for mounting disks and rear wheel gear spacer.
4. Purchase hinge for bonnet.
5. Purchase wire and switches.
6. Purchase/get magnet for speed sensor (bike magnet) and speed sensor switch (bike one).
7. Purchase bike brake cables (2x) and brake outer (4m ?) with cable outer end caps.
8. Purchase battery cable crimp end terminals (6 and 8mm ring holes).
9. Purchase harness mounting rings (8mm bolt thread).

Easter

2018-03-28

Try and fit bottom and sides, start on switches and wiring, electronics box, start on motor mounts.

1. Make switch mounting brackets and fit battery switches.
2. Cut aluminum sides to fit and pop rivet in place.
3. Fit harness mounting rings (will these come with harness).
4. Fit nose cone.
5. Cut bottom plywood to fit (use cardboard/thick paper template ?). (Need jigsaw/circular saw).
6. Fit bottom plywood (Need battery drill, countersink, drills, screw drivers).
7. Cut bonnet and opening driver area and fit. (Need to look at shape/design for this).
8. Cut behind driver plywood and fit.
9. Lathe out hole in drive gear and drill bolt holes. Mount to wheel with spacer.
10. Make motor mounting brackets (Aluminum angle and steel bits to be welded to rear subframe).
11. Fit brake cables temporarily.
12. Design and make electronics aluminium box.
13. Start cuting battery cables and fit.
14. Thank you letter for Town's Land Charity

If there is time:

• At the end cut and epoxy carbon fibre below batteries and driver.
• Spray paint king pins and front subframe struts.

Things todo in approximate order

1. Order: Tyres and tubes.
2. Harness: purchase
3. Harness: fit.
4. Drive: make rear wheel gear spacer.
5. Drive drill and fit rear wheel drive gear.
6. Drive: make motor mount and fit.
7. Drive: fit cogs and chain.
8. Batteries: make battery holders and fit.
9. Electrics: purchase wire, battery connectors, switches, fuses etc.
10. Electrics: Fit switches and main wirering.
11. Electrics: make electronics aluminium box/tray.
12. Electrics: fit electronics (Speed controller, computer, GPS, Telemetry).
13. Electrics: fit display and connect.
14. Electrics: fit wheel speed sensor.
15. Electrics: fit joystick and connect.
16. Electrics: fit horn.
17. Electrics: fit brake light.
18. Electrics: fit motor temperature sensor.
19. Brakes: cut and fit cables and adjust.
20. Body: cut and fit aluminium panels.
21. Body: cut and fit steering tie rod covers (aluminium).
22. Body: fit inside ply panels by front wheels.
23. Body: cut and fit plywood bottom and bonnet.
24. Body: add carbon/kevla fibre strengthening areas.
25. Body: cut, fit and shape foam sides.
26. Body: make nose and fit.
27. Body: make tail and fit. (Need to decide fixing mechanism).
28. Body: make windshield and fit with mirrors.
29. Body: make rear wheel covers.
30. Body: make front wheel covers.
31. Body: make headrest/fairing.
32. Body: make behind head fairing.
33. Body: fit foot ridges.
34. Body: paint and decorate.

Monday 15/10/2018

Things todo in approximate order:

Body work: Team lead - Martin

1. Attach sides to the car (after deciding on how they will be fixed)
2. Shaping of the sides - keeping them symetrical
3. Fit current bonnet. Replace with new bonnet at a later date
4. Make and fit the headrest
5. New nose
6. New tail
7. Make and fit windscreen
8. Fit outer wheel covers
9. Make and fit inner wheel covers
10. Fit rear view mirrors
11. Paint car

     Tools required for bodywork: Flood lights, hand saw, vibrating cutter, comb guide, router, sander for shape finishing

Electronics: Team lead - Terry

1. Speed controller software
2. Speed controller build
3. Display build
4. Telemetry build
5. GPS

      Tools required for electronics:

Wiring: Team lead - Rob

1. Brake light
2. Motor temperature sensor
3. Speed sensor

      Tools required for wiring: Toolbox

Website: Team lead - Tristan

1. Develope and publish new website on chosen platform
2. Update new / existing website weekly with new pictures and descriptions

3D CAD: Team lead - Joe / Tom

1. Inner wheel covers
2. Lower wheel fairings
3. Roll bar fairings
4. Wing mirror fairings

Other tasks:

1. Check over and test RR9 speed controller
2. Check over and test RR9 display
3. Repaint RR9
4. Update notice board in corridor
5. Update TV in entrance by hall
6. Update photos on main board in DT room
7. Sponsorship
8. Funds for a new trailer - write to trailer companies
9. Produce sponsorship stickers for RR10
10. Team logo - finalise
11. Replace wheel berings with new

   Winter Tasks:

1. Trailer - Strip and rebuild (wheel bearings - new, spare and jockey wheels).......................P1
2. Sponsorship.........................................................................................................................Ongoing
3. Test batteries and replace as required
4. RRX electronics including telemetry.....................................................................................P1
5. Speed sensor.......................................................................................................................P1
6. Motor temp sensor................................................................................................................P1
7. Bodywork aerodynamics (Re-make sides and nose for RRX, new tail for RR9, paint).......P1
8. Bearing bushes....................................................................................................................P1
9. Tracking (Both cars)
10. Team training (CAD/PICAXE)
11. Racing Simulator
12. Drill and tap spare gears
13. Foam protection (transit)
14. Replace motor on RR9 with new one after testing