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Old 03-23-2013, 03:24 PM   #298 (permalink)
Vekke
Mechanical engineer
 
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Join Date: Jan 2009
Location: Kitee (Finland)
Posts: 1,268

Siitin - '98 Seat Cordoba Vario
90 day: 58.56 mpg (US)

VW Lupo 3L --> 2L - '00 VolksWagen Lupo 3L
Diesel
90 day: 104.94 mpg (US)

A8 luxury fuel sipper - '97 Audi A8 1.2 TDI 6 speed manual
90 day: 64.64 mpg (US)

Audi A4B6 Avant Niistäjä - '02 Audi A4b6 1.9tdi 96kW 3L
90 day: 54.57 mpg (US)

Tourekki - '04 VW Touareg 2.5TDI R5 6 speed manual
90 day: 32.98 mpg (US)

A2 1.4TDI - '03 Audi A2 1.4 TDI
90 day: 45.68 mpg (US)

A2 1.4 LPG - '02 Audi A2 1.4 (75hp)
90 day: 24.67 mpg (US)
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Looking sweet and nice progress on the sanding going on. I know its hard sometimes to find power to do things as there are so many things to do and just one man doing them.

Someone asked a question how many hours it will take to manufacture fully working consept car from scratch its around 30000 manhours. This car is looking so nice that its at least that much when project is finished.

I would also keep the foam inside composite structure because its stiffens the body a lot plus the insulation help.

For glues testing I would make at least simple beam test. Take two or three similar size beams and and cover them with various adhesives. Meaning that at least test also real Epoxy resin. Cross dimensions 50mmx50mm and length 1.1 meters. Put so many layers of glas as you plan to use in the body. It might be more in corners but rough estimation about 6 layers of 300 g/m2 is at least enough (thickness about 2mm) twill glass fiber. you can also make one pillar so that you take out the foam from inside and see what is the effect to rigidy.

Let the pillars cure according to instructions and test them at the next day. Put the pillar laying on top of two stands which gap between is that 1 meter and start putting weight on top of pillar right to the center point. See how much stress it can take before breaking.

That wood glue might not soak into glas fiber as much as needed. that can be seen in the end of the test. So if there are glass fiber that is not hard your glue is not working properly. You can see something also from the cured part color it should be clear at least with epoxy resing. If its still "white" its not working properly.
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