Diamonite Electrathon America Racer

[Denny]

Panel bonding adhesives are being used to replace welding on modern cars. While I agree it would not be any good to join tubing together for a roll bar, for your bulkhead I believe it would be more than strong enough. 3M and SEM are 2 of the biggest companies.

 

[Master Hack]

Panel bonding adhesives are being used to replace welding on modern cars

Plastic cars glued together! Sounds great! Reminds me of the models l built as a kid. Maybe Revell will come out with a full size kit car?

 

[Denny]

Plastic cars glued together! Sounds great! Reminds me of the models l built as a kid. Maybe Revell will come out with a full size kit car?

No, these are steel and aluminum cars glued together. But if Revell did make such a kit you could sign me up. I’ll take a 67 vette!

 

[ezcome-ezgo]

Depending on how much strength you need, you could overlap the "skin" and even tongue and groove joint the foam core.

 

[Functional Artist]

Depending on how much strength you need, you could overlap the "skin" and even tongue and groove joint the foam core.

View attachment 151672

Hey Ez,

Quote from TUFFAK fab guide
"The design of the adhesive joint has an influence on the final strength of the bond. Joints should be designed in a way that transform tensile or compressive stress to shear stress. The larger the bonding area, the stronger the bonding."

Notice that the lower body panels, of the upper & lower sections will overlap, going down almost the entire length of the chassis
...which with such a large, bonding area, should provide for an excellent bonded "joint"
...I believe would be a "shear stress" situation too
...& it would double the thickness of the material in that crucial area

Also, the entire monocoque would be supported by the (3) bulkheads

The "outer skin" could/would then be bonded (with Epoxy) to the (3) bulkheads
...& also, mechanically fastened, with some "sideways" threaded inserts (I guess we can call them)

* Notice the middle bulkhead could/would also, provide
...an upper steering support
...a "dashboard" area
...& will be "hollow" (part of the leg tunnel)

 

[Functional Artist]

While working on another project, I came across some kinda thick, kinda stiff but also, kinda flexible clear plastic

It's from some Christmas ornament packaging
...but, I've been using it for making stencils

I adjusted the measurements (from the cardboard model) a bit
...to get a better "overlap" joint between the upper 1/2 & the lower 1/2 sections of the monocoque
...& drew up a new "lay out" diagram

I cut out the sections & used them as templates, to trace out the sections on some of the beforementioned clear plastic

Then, marked the bend lines
...& did some bending (just using a straight edge & hand pressure)

Then, simply aligned the "body lines"
...& "stacked" them up

Notice the "nice" over lap?

 

[ezcome-ezgo]

Cool. Now the mice can play.

 

[Master Hack]

" They" make threaded inserts specifically for plastics.

https://www.pemnet.com/wp-content/uploads/sites/2/2022/06/sidata.pdf

 

[Functional Artist]

I've been doin' some more CAD work

Still workin' with this Diamond body shape/style
...& the (2) piece construction

But, thinkin' it thru
...like how it (the monocoque) would "potentially" perform
...& about the "how to do it" (construction method)
...a few "red flags" popped up

So, first off, I tryed ta round the sides, in the rear a bit
...which should help "spread the load" across the transition, from the side panel to the back panel
...& rounding that "rear corner" off a bit, should help with aerodynamics too

But, the lower "corners" would still be "sharp"
...& the bottom rear "edge" would have a pretty "sharp" transition too

* Which IMO probably wouldn't "spread the load" very well
...& also, be "weak spots" or potential failure zones

Then, I worked on rounding them bottom "corners" off a bit
...maybe something like this

But, that "solution" would only round the "corners"
...& we would still have a pretty "sharp" bottom edge (transition from floor to back panel)

 

[Functional Artist]

Just workin' on a "bottom 1/2 for now
...& after several iterations

Now, I'ma thinkin' ta curve the bottom upwards a bit
...something like this

Then, curve the sides inwards
...kinda like this

It seems like this "concept" could be easily cut out of a 4' x 8' piece of most any, semi-flexible material
...should be pretty easily formed, into this simple shape
...help "spread the loads" across the body better
...& also, help with aerodynamics too

 

[ezcome-ezgo]

Honestly at this point might be better to ditch the "c"ardboard for the "c"omputer. It's getting mighty fancy.

 

[Master Hack]

Back to nuts and bolts. ( N&B) and hubs.
I borrowed a welder after making the excutive decision. (To weld and not bolt)
l was curious if the problem was me or my old welder? Its getting difficult to find coal to run it, anyway...
Hubs....
I welded the two together so they warp together.
I think l need a better welder & some practice.

 

[Functional Artist]

Whatcha talkin' about Willis?
...that's some really nice shiz

 

[Functional Artist]

Alzo/FYI
...the beforementioned creation with the "curved bottom & sides"
...is NOW to be used as a mold
...to make a bottom 1/2 of our monocoque out of fiberglass

Yes, were back to potentially using, fiberglass (cloth & resin)

I still think I could have made a monocoque out of a couple of sheets of polycarbonate
...but,
1.) that beforementioned rear transition bothered me
...& trying any curving or shaping seemed like a PITA
...& I couldn't "see" a good/nice looking outcome
&
2.) I found that a 4' x 8' sheet of 3/16" polycarbonate is ~$200.00
...& we would need (2) of them (1 for the top & 1 for the bottom)
...so, ~$400.00 for a "questionable" experiment...IDK...probably...NOT
&
$400.00 could/would buy an awful lot of fiber glassing materials

 

[Master Hack]

Had to dig down to the bottom of the bag o tricks for this cool gadget:
Getting ready to put more holes in this thingy.

https://youtube.com/shorts/RsCV_ONfd-8?feature=share

 

[Whitetrashrocker]

That spin speed makes me flinch.

 

[ezcome-ezgo]

The housing of the gauge is moving.

 

[Master Hack]

The housing of the gauge is moving

Yes it is. That was just a video demo.
The proper response would have been OOOOH and AHHHH!
Nothin gets by you guys!

 

[ezcome-ezgo]

Oh sorry.

OOOOH
AHHHH!

That's groovy.

 

[Master Hack]

Thats much mo bedder. Thank you!
even an optional groovy! Now thats groovy! No! Wait!
thats BITC*IN