How to Build a Racing Car

Introduction

Importance of the chassis in racing cars.
- Affects handling, driver ergonomics, manufacturability, etc.
Focus on design and construction of the chassis space frame.

Iterative Process: Extensive time spent on chassis design.
Rule Compliance:
- Follow Formula V rules for materials, dimensions, safety, etc.
- Created a dummy in SOLIDWORKS using personal measurements for fitting.
Ergonomics:
- Built a wooden ergonomics jig to test fit and comfort.
- Adjusted legroom by 100mm based on tests.

SolidWorks Drawings:
- Incorporated all car parts in the assembly.
- Designed brackets and mounts to avoid clearance issues.
Finite Element Analysis:
- Used Excel model for guidance on chassis strength.
- Additional strength from rule-required side impact protection plates.

Tubes and Drawings:
- Produced detailed drawings for tube placement.
- Used SolidWorks to manage tube cutting and placement.
Tube Cutting and Assembly Order:
- Precise order for cutting and inserting tubes to avoid welding issues.

Chassis Jig:
- Built with pivots for ease of welding.
Tube Cutting Process:
- Cut tubes in batches using a tube notcher and bench press.
- Considered outsourcing to laser cutting specialists.

Initial Assembly:
- Tack welding initial members in place.
- Built side members separately then attached.
Roll Hoop and Bulkhead:
- Positioned roll hoop on chassis jig.
- Temporarily braced and welded bulkhead members.
Forward and Upward Construction:
- Added bracing to maintain member position.
Longitudinal Rails and Cross Bracing:
- Installed main longitudinal rails before cross bracing.
- Used inclined braces for front support.
Final Member Installation:
- Focused on dimensions for mounting H-beam suspension.
- Ensured alignment to prevent chassis twist.