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Tom checking the rollbar height

Rotary Racer 8: Todo List

Plan

Build a new Chassis so that the Lads will fit. This will probably need a new steering system and require the batteries to be further back with a more stub rear. While doing this try and improve the aerodynamics. First start on new chassis design (VWT, steering etc) and try and get more funding. When we have a suitable design and the funding we can progress to building the new chassis. We will try and keep the old car intact as possible.

Improvements to existing car

Play with VWT to look at a more aerodynamic body shape. (All)
Look at new steering system that will allow the Lads legs to go further forward. (Martin,DanI,Ian)
Plywood base on bottom of car to reduce height.
More stub rear to allow driver to be laid further back and lower ?
New car horn. (Gareth, DanD,Ben,Terry)
Smaller front wheels ?
Improved Telemetry system. Improved software at both ends. better aerial. (Terry,Kevan,Gareth,Tom ?)
Driver communications. This could just be a software mod to allow messages on the LCD panel with flashing LED's. (Tom,Terry)
Wider rear tyres ?
Reduced throttle movement. Drill and fit grub screw at appropriate place. Fit smaller slider variable resistor.
Drill out new motor gears. may need to by smaller rea cogs or bigger front cogs.
Steering bar not so close to lads bits ...
Fit dual rear disk brakes or dual front brakes. We probably need some new disk pads at least ...
Tidy up wheel covers.
Colour and Style.

Date	Description
9/12/08	VWT Testing. Blender and Paraview should have been installed on the school computers in the CAD lab. Car Horn Development Fit motor back into the car ?
16/12/08	Meeting, VWT, CarHorn
6/1/09	Meeting, Car Designs, Steering Design, CarHorn
13/1/09	Look at Car design
20/1/09	Decide on Car design. Create more detailed design and work out major components needed. Play with steering designs in wood Car Horn Measure currently used tube and ply Order main items needed: Tube, Tube Joints, plywood
27/1/09	Bending main tubes Car Horn Steering design/build
3/2/09	Bending main tubes RR7: battery box Car horn
10/2/09	Bending main tubes Cut some cross tubes and start joining main tubes RR7: battery box
24/2/09	Make up frame RR7: Battery box
3/3/09	RR7: DriverSize: Decide on new steering, hollowed out nose cone and/or larger rollbar Make up frame
10/3/09	RR7: Move steering back And tubes to frame Design rear subframe Design steeing
17/3/09	RR7: Move steering back Make up rear frame Make up steering
24/3/09	RR7: Shorten steeing bar and move driver end mounting forward 20mm. RR7: Raise Rollbar 40mm using two Aluminium bar extensions at the bottom end and a longer rear bracing bar. RR7: Fit blue LED RR7: Pit Make up rear frame Design steering
31/3/09	RR7: Fit front plywood sides and nosecone sticking boatcoat down. RR7: Refit rollbar. RR7: Cut and refit windscreen. RR7: make up cushions for smaller kids ? RR7: Check electronics RR7: PitStop LED RR7: Look at fitting radio's to car. RR7: Check batteries with leads fit RR8: Weld mounting plates to rear subframe.
21/4/08	RR7: Refit windscreen. RR7: Finish pitstop LED, upload new car computer software RR7: Change gearing to 19:55 RR7: Slope underside of nosecone up 50mm at front RR7: Change to use twin rollbar supports RR7: Get ready for race RR7: Test RR7: Pitstop practice RR7: Check on bits for race, pit-board, drivers manuals etc RR7: Look at fitting radio's to car. RR8: Fit rear subframe RR8: Look at sterring design (We have rose joints).
	Terrys House RR7: Change to use twin rollbar supports Paint new plywood bits Check electronics Check wheel alignment
26/4/09	Corporate Challenge
28/4/09	Post race meeting Fit Rear Subframe Cut out and attach plywood base Steering fit
5/5/09	Fit Rear Subframe Decide on steering, design and build some components Look at fitting disk brakes Car Horn
12/5/09	Modify front of frame Steering build some components Make list of materials needed to buy Car horn
19/5/09	Steering build some components Measure and make aluminium stub axles. Drill, thread and lathed down to fit subframe. Length should be so that tyre outers are 600mm apart. (Wheel bearing to tyre outer 50mm) so overall axle width 500mm = 600 - 100. Leave enough hole/thread so we could move wheels nearer together to completely fair in in the future. Adjust chassis to fit plans. Straighten out rear. Battery floor and rear fold up design/size and look at fitting (10/12mm ply with inset hinges (piano type ?) Design motor mounting Design steering bar (use old one from RR6 with welded on track rod lever) Make up steering bar bearings (nylon bushes drilled, cut and reamed). Make up aluminium plate with bolt bearing for other end. Car horn Make list of materials needed to buy
26/5/09	HalfTerm Fit rear wheels Build steering system, start fitting Fit seat mouning bars and steering joystick bar Work out where to put seat and measure
2/6/09	Terrys House Steering Extra tubes Battery mountings Test how to shape, smooth and paint the foam.
9/6/09	Finish steering fit wheels Fit steering bar (Need 130x50x4mm aluminium from front bracket. Add extra driving area tubes and side impact bars. Look at fitting seat and work out amount of cloth required. Mark out and cut bottom ply (shaped around wheels and 2mm bigger than aluminium frame) Car Horn
16/6/09	Fit side impact bars Steeting fit Fit bottom ply add thickening panels under driver (extra 4mm layer) Make seat (Sew canvas with foam inside) Work out cog spacer size, make cog spacer. (Lathe, drill) Make and fit motor mounting How to fit brake calapers Fit Motor
23/6/09	Cut and fit top ply Make brake caliper mounting spigots and cut caliper mount plates to fit Design for single to dual brake cable splitter. Design roll-bar Car horn should be completed Fit steering arm and size up steering
28/6/09	Terrys House Fit side side body panels and start to shape. Make single to dual brake cables unit (Can buy if time is tight) Fit Brake lever and Throttle
30/6/09	Drill and thread further the steering units (10.5mm drill) Design and make rollbar Cut and fit electronics tray Cut and fit aluminium brackets for power switch and car horn. Fit steering arm, bits and brakes Further shape side panels Cut and fit rear top ply Cut out, shape and fit front nose and rear foam parts. Install Car horn Cut and fit some wires. Rear flap holding mechanism
2/6/09	Terrys House Install Electrics/Electronics Telemetry and Software improvements should be completed Install Car horn Finish steering
4/7/09	Martins House Cut out, shape and fit front nose and rear foam parts. Cut and fit rear top ply ? Shape and sand foam bits Paint
7/7/09	Fit rollbar Finish around roll-bar and bodywork Fit internal wheel covers Fit internal protection foam Fit rear door foam Make rear door catch Set driver opening size Fit electronics Test Car, around playground (pushing) Pit stop testing
8/7/09	Terrys House Finish electronics Misc finishing bits Add next layer of paint Apply Transfers etc
11/7/09	Test car
12/7/09	Central South Heat
13/9/09	The Western Regional Heat
27/9/09	The Greater London Regional Heat
	Extra Bits Optional: make new battery trolly to match car height.

Rotary Racer 8, Renovatio: Todo List Post Build

Improvements to existing car

Fix seat rip. More bucket shape. (Martin)
Joystick angle (DanI)
Reduced throttle movement. Drill and fit grub screw at appropriate place. Fit smaller slider variable resistor.
Fan replace and extend guard. (Terry,Gareth)
Aerodynamics Improvements (Gareth)
Stabalise cars exterier.
Replace wheel coverings
New Tyres
Check motor

Date	Description
21/7/09	Look at seat and take out for fixing Takeout joystick for fixing Takeout throttle for fixing Replace Fan Extend guard Look at aerodynamics
	Over Holidays Fix seat Fan replace and extend guard Put car back together Make any minor aerodynamic improvements Check motor
8/9/09	Fit any bits back together Check drivers fit ! Make behind head filler Test car Practice pit stops Measure rolling resistance Improve rear section
	Terrys House Fit new tyres (making sure they fit) Adjust tracking Fit behind head filler Fit new power switch
13/9/09	The Western Regional Heat
	Future bits Reduce throttle movement Aerodynamic improvements Battery handles Improve Aerodynamic's around driver Improve rear section Louder horn Wider tyres Stabalise cars exterier. Replace wheel coverings
15/9/09	Post race meeting Playing
22/9/09	Make up battery insulated box to test warming the batteries Perform a test of discharging the batteries at different temperatures. Add front edge to roll-bar Fill dents and paint Start making rear pointy bit
27/9/09	The Greater London Regional Heat
29/9/09	Short what to do meeting Make up battery insulated box to test warming the batteries Aerodynamics VWT tests Making rear pointy bit Display panel for info Test battery acid with hydrometer in old RR7/RR8 batteries Test and cycle "New" batteries Improve school displays Write up Dunsfold Race (Dawn)
6/10/09	Make up battery insulated box to test warming the batteries Make up new battery pack (need packing tape machine) Measure wheel bolts, to get spare wheel bolts Fit new front wheel bearings Do some aerodynamic changes and test with the VWT. If good implement the improvements Improve electronics/telemetry battery charge indicators. Making rear pointy bit Display panel for info Cycle new batteries
13/10/09	Do some aerodynamic changes based on VWT tests. Behind front wheels slope and around driver slopes. Improve battery trolly to fit battery boxes. Check over car. Refit rear piece where broken, needs glueing and re-positioning.
18/10/09	The Greenpower Final