Tube Frame Design

[CFECO]

Per the structural fiberglass manufacturers web site, these components can be mechanically connected. My plan for the production of the Auto X-Prize car line, was to quick connect the tubes with sheet metal and rivets, and then down the line the joints would be covered with fiberglass and or carbon fiber.
Welding is a craft, good welding is an Art. Welding a space frame car involves vertical and overhead welds, unless a means to rotate the frame is available, a car rotisserie. Fiberglass work is labor intensive, but the actual labor is low skill. Today I think I may try to use PVC fence rails to fab the chassis and then fiberglass over the joints with multilayers at the joints. I'll get some and try some sample joints....to be continued.

[jumper]

I just read your post and it's very interesting. Have a question. I'm not sure if I understand or not, but is it possible to do a frame with no welding?

thanks

Originally Posted by CFECO

If you are going the tube frame route, you might look at composite tubing. There is "Pultruded" fiberglass tubing in many shapes, round, square, I-beam, flat, angle, etc., which can be stronger and lighter than steel or aluminum, plus no exotic welding skills are need to join the tubes.

[CFECO]

One could do a Monocoque frame of folded sheet metal and rivet it together, strengthened with adhesive. Or Fiberglass of the same design as the sheet metal, or fiberglass tube with gusseted joints. Just to name a few possibilities.

[jumper]

I had to look up Monocoque, but what you're talking about sounds like just what I want. I like the first suggestion. It seems like an easy way to go for my first build. I'm going to have to look into it more. I really appreciate your post and it gives me some ideas.

I have one question... I looked at Harbor Freights and they have some rivet guns. Would a hand gun riveter be ok to use? This may be a dumb question but I'm just learning.

[CFECO]

"Maybe", I have not had any experience with that HF tool, I am not thrilled with most of their stuff. There is a light, home made car on Ecomodder somewhere, that was build with flat sandwich composite panels. You might look up homemade aluminum aircraft construction, Aircraft Spruce company supplies a lot of materials for the home built aircraft community, and have a lot of experience with them. They have construction books, tools, and materials. For high quality rivet tools, I'd find out what you need, and go to Ebay or Craigslist for Good used over HF if they were going to be used a lot.

[CFECO]

Search for Autospeed light weight car here at Ecomodder, the build series should come up.

[jumper]

I haven't looked on Craigslist yet, but I did read the thread you suggested. There were some other threads that were related and I'll read them too. Thanks so much for the help. This new information (for me) really makes it where I can see how things would work.

You're a good man

[jumper]

I've found a good EV body to build and would fit the use of rivets. Next thing I need to understand is what motor to get. I've read a number of threads, but they are mainly talking about something specific about a certain motor. I've read about forklift motors too.

So here's the question... If you're dirt poor, what motor would you use?

thanks a bunch...

[CFECO]

For a light car I'd look at golf cart motors. You could use two, one geared low for acceleration from a stop, and one geared higher for higher speed, or use a CVT belt drive from a snowmobile.

[jumper]

Thank you so much for all the help. What would be easier.. the golf cart or the CVT thing? I think (but not sure) that I could find a golf cart before I could find a snowmobile. I haven't actually looked for a snowmobile because in the south, there are not many around

EDIT: I guess I should ask which is better... golf cart motor or CVT.