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We placed 6th overall in the middle of may. :rock: Were now starting on next years design, plus we have our formula hybrid frame in production now.

http://www.sae.org/students/fsae2010results.pdf
Good to hear you guys are getting a Formula hybrid team up and running. We would have had 1st again this year if it wasn't for just a few little things. Very frustrating.

There are 2 types of people in formula hybrid. The ones who play by the rules, and those who play by the spirit of the rules. The second is much more restrictive. :) I suggest the first.
 

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Discussion Starter #42
hey everybody!

all the info about the cars makes me want to build one! what kind of engine are you using in those?

the camlocks look great, and i will try and do something like that, however, i am trying to make it as flush as possible since it shouldn't need to be opened up very often. not really storage, just electronics.

i did get some work done yesterday. i got the tail section close to finished, and the tail-ight mounted. there will be some bondo work to make everything smooth, but i am reticent to start that till ALL the welding is complete.

preliminary fitting:


Cut to size:


back welded on and tail-light in




Side-panel work in progress


Once i get those fit, i still have to fill this hole:


hopefully i will get those at least tack welded together today and mounting tabs put on.
 

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Our car was a boosted 250 single this year. It was tough to get the power we needed (never quite made it) and ended up suffering in fuel economy trying to make power with our turbo setup. Fuel economy was the main reason we went with the 250 too, which went own the flusher. We have a good group of drivers, all from racing backgrounds, so that made up for our car's deficiencies. The winning team ran a 450 single. In the past, we have ran many different setups. Most common for us was the 600 from the F4i, but we have also ran a boosted CBR 250 I4 and a boosted Aprilia 550, both of which did well aside from catastrophic engine failures at the end! :p

Here is our engine setup in design:


After I rearranged our intake following dyno time:



By the way, your bike is looking good. I don't have the patience for fabricating sheet metal...
 

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Wow that is a sweet setup. We ran the tried and true f4i 600. Have been for the last 6-7 years or sobut we're switching to a yamaha 450 single next year for fuel economy too. May run a monocoque next year but it hasn't been very good to us (except for one year we finished 5th).

Knifemaker are you TiG or MiG welding? A lot of formula teams can use a great welder. We only had one main welder this year and it was a super overload for him. Great work. Are you a machinist?
 

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Discussion Starter #45
Wow that is a sweet setup. We ran the tried and true f4i 600. Have been for the last 6-7 years or sobut we're switching to a yamaha 450 single next year for fuel economy too. May run a monocoque next year but it hasn't been very good to us (except for one year we finished 5th).

Knifemaker are you TiG or MiG welding? A lot of formula teams can use a great welder. We only had one main welder this year and it was a super overload for him. Great work. Are you a machinist?
I am MiG welding with flux core. To be perfectly honest, my welding sucks. that is why i grind everything flat. I dont know how much if it is the welder and how much if it is just inexperience, however, i do know that only through practice will you improve, so.. practice i will. i do know a couple really good welders though...

I am a machinist... how did you know?
 

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Discussion Starter #46
well, didnt have much time to work, but i did get the side covers at least put together.

All the fitting was done, so all i had to do was tack weld them, pull them off and finish welding the seam, then cover up my bad welding by grinding everything flat:


here is a rough fit.. after grinding... still needs alot of fine tuning:


profile:


put some primer on there to keep it from rusting till i can fine tune them up:


wanna see some ugly welding? bondo coming soon!


i am still trying to figure out how i am going to secure both the side-panels and the tail... ideas would be helpful.
thanks!
~Chris
 

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I am MiG welding with flux core. To be perfectly honest, my welding sucks. that is why i grind everything flat. I dont know how much if it is the welder and how much if it is just inexperience, however, i do know that only through practice will you improve, so.. practice i will. i do know a couple really good welders though...

I am a machinist... how did you know?
I know that fabricating stuff like that is pretty **** tough. It takes more skill than people would like to believe; skills that a machinist would have. You also seem to know what you're doing.

You're not alone with the welding quality. I've been tinkering with tig welding for over a year and my stuff still sucks. It's an art. Looks good so far.
 

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A tig weld would be the way to go on that stuff, with a 1/16" or smaller tungsten and the machine set way down to around 20-30 amps and just fuze it without adding any rod.

Does'nt look too bad for just flux core though, I use it at home in my little home depot lincoln welder and I can't do any better than what you have there and I'm a four stage certified structural and pipe welder lol....that stuff just welds like dookie, especially without gas.


The only thing I'd do differently is bring down the front of your tail cap to thin out the side profile and add more angle to the tail....at least to match the angle on the seat.

And to secure it you could add a flange on each side of the tail with slots cut, and add some notched tabs to the top cap that fit into those slots and when you push it back the fingers would lock into the slots you put in the flanges on either side.

And to secure it all you could put a flange across the front of the top cap with a couple holes so you could use some push-pin fasteners to hold in in place....or put the flange on the tail and put the push-pin fasteners in from the top.
 

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Discussion Starter #50
A tig weld would be the way to go on that stuff, with a 1/16" or smaller tungsten and the machine set way down to around 20-30 amps and just fuze it without adding any rod.

Does'nt look too bad for just flux core though, I use it at home in my little home depot lincoln welder and I can't do any better than what you have there and I'm a four stage certified structural and pipe welder lol....that stuff just welds like dookie, especially without gas.


The only thing I'd do differently is bring down the front of your tail cap to thin out the side profile and add more angle to the tail....at least to match the angle on the seat.

And to secure it you could add a flange on each side of the tail with slots cut, and add some notched tabs to the top cap that fit into those slots and when you push it back the fingers would lock into the slots you put in the flanges on either side.

And to secure it all you could put a flange across the front of the top cap with a couple holes so you could use some push-pin fasteners to hold in in place....or put the flange on the tail and put the push-pin fasteners in from the top.
thanks for the info on the TIG. i would love to get my hands on such a welder.. however.. my funds are limited to i am stuck with the flux MIG. i am someone happy to know it isnt just me. =)

sadly i cannot really change the angle of the tail too much as i have already got it fit and holes drilled. but the side profile is going to get cleaned up, u just have to decide which side i want the flange on the cap or the tail. i am leaning towards having the flange on the tail itself so the cap is simpler. i did make a flange on the side soto, so it will line up and i can blend everything with bondo. it is really ugly right now, but i will get pics once it has been cleaned up a bit.

i should have a progress report tommorow with fastener s for the tail and side covers.
thanks!
~Chris
 

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the reason the welds look like that is the flux core stuff. i have a small mig welder and with the flux core my welds look just like that so i switched over to using shielding gas and now i can make some real welds haha. your bikes look sweet !!! what kind of knives do you make ? do you sell them online ?
 

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Discussion Starter #52
the reason the welds look like that is the flux core stuff. i have a small mig welder and with the flux core my welds look just like that so i switched over to using shielding gas and now i can make some real welds haha. your bikes look sweet !!! what kind of knives do you make ? do you sell them online ?
thanks! i guess i need to look into getting some gas. i know i can use it with my welder.
thanks on the bike! hopefully this last one will but finished quickly.

I have made a bunch of different kinds, but i particularly like the japanese style blades. you can see pretty much everything i have worked on in the last while here:
http://picasaweb.google.com/Knifemaker87 i do have one up for sale right now, and i sell most of them on the knife forums i am a part of.

thanks
~Chris
 

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Discussion Starter #54
Like that link.Some very cool stuff,love that crane Katana especially.Some how I expected no less.
thanks so much! i am a but OCD so i tend to work feverishly on what has my attention at the time. Now i am just doing my best to complete the things i start. I made myself finish that sword before i started this project. =) glad you like it.

small progress report here...

i figured out how to mount the side panels and probably the tail as well.

I picked up some of these from the hardware store. stainless steel bolts!


so i drilled a hole though both the panel and the frame, widened the hole for the insert, and ground a recess so after welding it would be flush:


and after it was welded and ground (kept a sacrificial screw in it to keep crap out of the threads)


the other mounting point was easier, as it was just a tab welded to the frame with once of those nuts welded on the back. and here you have the mounted panel.


it still needs to be fine tuned before it gets copied in CF, but we are getting closer

I also made a template for the under-tail


it will be mounted by a couple tabs as well, and will be the easiest part to make in CF (and most likely the first too)

more to come on Saturday
thanks!
~Chris
 

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I was just thinking about the welding machine, If yours came with a set of gauges like cheapo lincoln did you could use Co2 for sheilding gas. The other day I was talking to a friend of mine and he said he just uses a large paintball gun tank with a valve on it for his at home flux core setup.

That would help the keep the welds a bit cleaner and probably help prevent some of the blowouts.
 

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Discussion Starter #58
Wow, you really are a god-awful welder. ;)

Looks great, though. Can't wait to see where this goes!
haha! you know it!

I was just thinking about the welding machine, If yours came with a set of gauges like cheapo lincoln did you could use Co2 for sheilding gas. The other day I was talking to a friend of mine and he said he just uses a large paintball gun tank with a valve on it for his at home flux core setup.

That would help the keep the welds a bit cleaner and probably help prevent some of the blowouts.
My machine has an input for gas, but i dont think it would work as there is something wrong with the actual nozzle. i think my welder is in the way out. i didnt get a set a guages with mine.. it is much cheaper than a lincolin electric. My freind has a lincolin with gas and i can weld pretty good with that... maybe it is time for an upgrade!
 

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Your knives are impressive, I esp. like the Damascus drop point.

Looking fwd to more of this thread, thanks for sharing.
 
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