CFECO's X-Car Project Re-Do

[Giovanni LiCalsi]

Originally Posted by freebeard

image-1871.jpg Photo by sunworksco | Photobucket

This is—as they say—relevant to my interests. I visited www.inrekor.com but didn't find this drawing. Where is it from?

The projects they show go way beyond the refinement of that design.


Can non-flat parts be cut and folded like this, or must they be maufactured in 3D?

The aluminum must be cut, then formed. Then the polypropylene foam board must be heated in a steam cabinet until it is malleable for forming into the shape of the aluminum part. The parts can be laminated after they cool and dry.

[CFECO]

"Crash tests have proven it among the strongest chassis.
All it takes is waterjet cutting the aluminum and polypropylene sheets, then bonding the sheets together. It's not that expensive."

I would have to see $ with shipping, and long term fatigue results. There are many other Composite Sandwich construction methods with a track record, and
"not that expensive" is highly relative. I'm still trying to find a "reasonable price and availability" for pultruded composite rectangular tubing in small quantities.
I don't have a water jet cutter, and I bet they are not cheap.
I did a quick look at their site and did not investigate very far, had to make dinner, but I did not see any completed vehicles with a long history.

[CFECO]

OK, I found a price, 6900 Pounds Sterling, not including 1400-1600 more for suspension components. Not in my ballpark, yet.

[Giovanni LiCalsi]

The cost is low if you have the aluminum and foam waterjet cut at a shop. It will cost less than $500.00 to cut all of the chassis parts, if you have the parts in a cad drawing.
The 3-M adhesive is not that expensive. Their are multiple ton presses in The San Francisco Bay Area that can press the laminations together. It only needs to be in a press for an hour.
The chassis panels go together like Lego pieces and the fastener lugs are incorporated along the edges of the panels in strategic places. Inrekor panels were designed for simplicity and affordability.

[freebeard]

I read the story about the flying canoe. So here's a picture—in the rafters of Hutch's bicycle shop is a dugout cedar Soapbox derby racer from IIRC 1941.



I like the rear suspension. it's similar to the Austin 1800



Are you working with this material?

[Giovanni LiCalsi]

I'm planning to use Alulight aluminum foam panels.
Nice soap box racer.

[freebeard]

It was CNC'd (cut 'n chopped) out of a cedar billet.

[Giovanni LiCalsi]

Check this video out.

Sculpting a Woman's Body - 3D CNC Foam Carving with FROG3D - YouTube

[aerohead]

Originally Posted by Giovanni LiCalsi

Check this video out.

Sculpting a Woman's Body - 3D CNC Foam Carving with FROG3D - YouTube

I believe that Scaled Composites is doing aircraft fuselage this way with a 5-axis router,with foam billet as long as 35-feet.

[Giovanni LiCalsi]

Great time saver!
I have a friend that used to be employed at Scaled Composites.