Each student team builds a car from the ground up to travel as far as possible in one hour on only 72 lbs. of lead acid batteries. We race against lots of other students and adults in towns and on race tracks all across this country on the weekends from March to July. We learn a lot and have tons of fun! This website documents our building process. Please leave comments and/or questions!
Please scroll down to see our recent progress.
2014-2015 Electric Car Team
2013-2014 CHS ECar Team
2011-2012 CHS Ecar Teams
2012-2013 CHS ECar Teams
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This week I have been working on the front axle fabrication and assembly. The first part of this project was I needed to measure and calculate the size and shape of the part. After I finished rough drafting the part I then rough cut out the pieces that make the parts. Then with the rough cut parts I finalized the pieces and welded them together.
Coulter did the tutorials on Solidworks, but he was not ready to build the nose yet. He then had to get 10 facts about aerodynamics for the new nose design. He learned some new stuff that he did not know before. For example he learned that a dimpled surface is more aerodynamic than a flat smooth surface. Another thing was that there is a high amount of air pressure on the front end of the car. With these facts Coulter will make several 1/10 scale models to see which one is the best for the real nose design (more will be told in part 2).
I recently added a boat-ail to car number 169. Next, I started by cutting out shrink wrap to the desired shape of the boat-ail. Start by taping the cover to the edges of the boat-ail and make sure it has extra shrink wrap that over lapse(the wrap will shrink, so it is good to have extra). Next, set up your heat gun and start heating the plastic how every you choose to do it, but make sure you get all the wrinkles out of it. Same process for the sides, only what I did, I took the shrink wrap and wrapped it from one side of the car, under the bottom and up to the other side. Repeat the same heating process to the plastic and your done.
In the photo to the right you see me welding. I currently just got my fillet skill. I’m proud to say that i know have a skill in which i can do work in.
Also i have done a lot of fillet tacks so my steering system has been put together.I need to finish it, and then get my skill so I can fully weld out my car.
The next piece for our car that I started working on a week and a half ago are the kingpins. The kingpins are the joints that go in the front of the car for the wheels to make them able to turn. First I cut two pieces of square tubing to 5 3/8 inches on the chop saw. After cutting them I grinded, squared, and leveled them until they were square and about the same length as each other. Next I cut four pieces of O-A metal with the O-A torch to the width and length of the tops and bottoms of the kingpin pieces. After cutting those pieces I grinded them to make them flat, smooth and level with the sides of the kingpins. Next I welded those four O-A cuts to the tops and bottoms of the kingpins. Then I squared them again and got them checked by Mr. Hipskind. Finally after getting them checked I moved onto drilling holes in the center of the tops and bottoms of the kingpins. Currently I am still drilling with the mill, but soon I will finish and move onto the next piece of the car that Mr. Hipskind has to offer!
Hi my name is Dean Hovinghoff and I have been working on this year’s new electric car. Two of the things that I have been making are a wheel and roll bar. The roll bar was a challenge because i had to bend it by hand. The wheel took a while to make because of all the spokes and adjustments that I had to make. The wheel helped to teach me to be patient.
So long and till next post,
Piece number three of front axle.
For this post, I will be talking about the bottom assembly of the car, I will also be talking about the front axle. The first project of this year for me was the bottom assembly. After I finished that project I started working on my front axle
The bottom assembly took the longest of these two project. The first part of this project was drafting out this part on a ply wood board. After finishing drafting this I bent two 45 degree bends in opposite directions. After we fixed and errors that occurred during the bending processes we then welded on two rear forks to hold the back tire. After we welded that piece I started to work on the front axle.
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For this post, I will talk briefly about how I made a boatail for car #169. For the lower part of the tail, I cut out, clamped, and tacked two angled metal pieces to the lower part of the car(just above the motor). After it was in place, I finished by welded out the part so it would stay secure to the car. Where the angled pieces meet, I cut out 1/4″ round stock piece and tacked it there(as level as possible, going in the vertical direction). Next I cut out two more round stock pieces, from the roll bar, I tacked them so the ends met with the vertical piece(tacking that to finish). I also added extra support stocks so that the boatail would be stronger. Now that’s a boatail!!!
Coulter is back for his 2nd year of Electric Car as well as Shawn and Erik. Coulter will be working on car #242 this year. He has already made is list of15 things to improve in the car. The biggest one he will do is putting a new nose on to the car. This project will push his building and geometry skills to their maximum. At the time of this post Coulter is working on Solidworks, a program to help him with sketching the car nose before building begins. He is doing good at the moment and he hopes to get started on the nose soon.
The pictures hear of Simon and I (Dean not pictured) show you what us new guys have done so far for our car. We first learned how to use the mill and bend tubing accurately. The mill was used for us to make very precise and accurate slots in the metal for our rear forks. After we finished those activities we drew on a piece of plywood the layout for the frame of our car. Then we bent 76″ long pieces of square tubing and fit them to the plywood. Next Simon and I, while Dean worked on the roll bar and fire wall, practiced tac fillet welds and tac butt welds to attach the rear forks to the upper frame. After our practice welds looked good we tac welded the rear forks to the upper frame. Now currently Simon is working on the front axel and I am working on the king pins. I will kept you all posted on how are team is doing and how we are progressing.
In the photo to the right you can see a “bushing” that I have placed inside. In the firewall I drilled a hole up to 5/8″ outside diameter so the bushing would fit. This is my first project as an advanced guy. I’m trying to replicate a steering system.
In the photo above I am working on my fillet skill (welding) to get the bushing secured inside it. I know it is bad but it was my first time so I’m planning on getting improved from there.