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Old 04-26-2017, 01:48 PM   #721 (permalink)
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Originally Posted by Grant-53 View Post
If wind tunnel time is pricey look around for someone with a camera drone. You could do tuft testing on a lonely road with the drone.
That would require a functioning car - which would be a lot more work. If I can at least test the aero, I could make molds and new body panels that could be used on a much more conventionally built chassis. And possibly get to a working car with less time / money / effort.

Another way to go, that I have been thinking about, is to build a new prototype with the method used for the Trev:


Which is a folded "box" of composite sandwich panels, with foam added on the outside. This is MUCH quicker and has much better 3D accuracy, and has structural strength built in.

Sincerely, Neil

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Old 04-26-2017, 01:51 PM   #722 (permalink)
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Camera drones are good for maybe 25mph. Racing drones are good for 120mph.

I suggest a camera on a tripod at the center of a 100ft circle. That way you can characterize cross-wind flows.

NeilBlanchard: I've watched the adventure over the years and wondered about starting over. That's a lot of work to just melt into a puddle, but you've learned a lot and I support your eventual decision.

I've thought about an Inrekor style chassis, but made with swing-door material.



Last edited by freebeard; 04-26-2017 at 02:03 PM..
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Old 04-27-2017, 12:07 AM   #723 (permalink)
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Convert the body to polygonal models of different sections then use Pepakura to make a folding pattern.

To achieve symmetry, figure out how to make a mirror pentagraph with a 1:1 ratio. Then you hand shape all of one side. Build up the other side with material thicker than needed everywhere. Trace the finished side with a stylus while a router mirrors the Y plane (in-out from vehicle axis) on the other side while moving the same as the stylus in Z and X planes. A 2 axis tilt on the stylus, copied by the router, would help reproduce finer details.

With a stylus and router bit of the same shape and the positioning correct so it's not carving too much or too little, it would make fast work of finishing a body plug for making molds.

In short, like a giant Copy Carver that works in more than two axes. If it fails, hack it up with a pair of axes.
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Old 04-27-2017, 04:34 AM   #724 (permalink)
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I'm not sure how the Pepakura Designer software helps with routering foam.

However the peel pattern it generates could substitute for the stage of hammer-forming sheet aluminum that Randy Grubb uses. Make a wooden buck that egg-crates together like he uses. Make one half, dissassemble and reassemble in reverse for the other half.
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Old 04-27-2017, 05:42 PM   #725 (permalink)
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I have been looking at some paper model software and the HPV Shell Design program of Wayne Shook at recumbent.com. The tub I might try to make from my stock of 9mm aluminum honeycomb (Testori America) per cut and fold and the skin from 0.062" ABS since I would not be making a mold.
There are new drone models coming out each year and our son just bought a DJI Phantom which goes right fast. When he gets proficient he could do highway speed camera work for tuft testing for say $200/hour.

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