CarBEN EV5 Full Sized Prototype Construction - 5 Seat Electric Car From Scratch

[Galane]

I want one of these!

http://www.youtube.com/watch?v=nITLI_WcnuM

Homebuilt 5-axis CNC carving the foam core for a boat.

For a project like your car, could carve out two halves to glue together, with alignment pegs to ensure it's a perfect fit.

[NeilBlanchard]

Yes, that looks pretty sweet!

I am going to bring my CarBEN EV project to the Framingham (MA) Earth Day Festival, which is happening on April 27th 11:00am-3:00pm at the Framingham Center Common; between Vernon Street, Edgell Road and Route 30; just north of the Framingham Center exit on Route 9.

What I have so far is the entire chassis built from foam and close to being ready for fiberglass. Here's my photo album of the construction process so far: CarBEN EV Concept Photos by NeilBlanchard | Photobucket

Please come if you can, and see the CarBEN EV5 that I have been working on for several years!

[JethroBodine]

I've been trying to think of a good excuse to come down and check it out. No promises, yet.

[2007 ion2]

that cnc would be perfect for things like this!! you could even put a bigger bit on for rough cut, then a smaller bit for a finished cut, but I also noticed it has a tipping head, so that might not even be necessary, since you could just program it to make the contours like that...

niel, that means you have just under a month to get it in fiberglass

[NeilBlanchard]

I'm not going to get much fiberglassing done until we have nights consistently above freezing. I may cut out some/all of the side windows, though, and I'd like to get the hood to fit in place.

[turbothrush]

Originally Posted by Rokeby

Any crack, tear or puncture, no matter how small, that allows water to penetrate through either skin has to be prevented. Once water gets into the structure it essentially can't be removed. As as result, the structure gets heavier over time. By itself, water will cause delamination of the 'glass-foam-'glass structure. Over time, small amounts of water will travel throughout the structure. When exposed to freezing temps it will turn to ice which will pry the laminate apart.

Rokeby

Excellent advice. This already happened to me on my project. I got some delam because it wasn't totally encapsulated and I left it outside in the weather for a few days . I can see that I need to be more careful about this .Thank you

[3-Wheeler]

Originally Posted by NeilBlanchard

I'm not going to get much fiberglassing done until we have nights consistently above freezing. I may cut out some/all of the side windows, though, and I'd like to get the hood to fit in place.

Neil,

Question: does the foam shape have enough self supporting strength to hold it's shape if you cut windows and such without any glass applied?

When building the tail, I continually put glass on the inside to give the foam enough supportive strength to avoid distortion, while adding yet more foam.

Just a question my part about your shapes current strength.

Jim.

[HydroJim]

Originally Posted by 3-Wheeler

Neil,

Question: does the foam shape have enough self supporting strength to hold it's shape if you cut windows and such without any glass applied?

When building the tail, I continually put glass on the inside to give the foam enough supportive strength to avoid distortion, while adding yet more foam.

Just a question my part about your shapes current strength.

Jim.

I'm going to guess yes. He'll be removing structural material, but also lightening the load. With the big hatch/rear door, there isn't much material on the top to support.

[NeilBlanchard]

I will wait until I have the roof and ceiling as smooth as possible, but yes I think the roof will be strong enough for the side windows to be cut out, without fiberglass. I may need to get the windshield and the vent piece at the base of the windshield in hand before I get the hood in place, though.

I think I will do some patterns (out of heavy paper card stock?) of the side windows, so I can flip them from one side to the other, to get them symmetrical and that is probably what I'll show at the Earth Day Festival.

[freebeard]

My money's on the upper rear corners of the roof/sides move laterally 1/8-14" with body flex out on the road. Squeak! Squeak!

Sorry.