The summer edition of the Newsletter is here!  Download it to see all of the recent going-ons on the Northwestern Formula team.  This version features articles on the machining of the uprights by Ben Kolodner and Joshu Jund’s progress on the nosecone.  This newsletter also spotlights CAPE (Center for Advanced Product Evaluation) Testing for their contributions to the team.  The link to download it is right below this, make sure to take a look at it!

Summer Newsletter

Build Progress, Composites, Engine, Publicity Build Progress, formula, newsletter, sae

Things are really starting to go now!  Here are the latest pics of the frame:

Front and tub are fully welded.  Rear section and tabs are being fabricated as this post is being written.

Build Progress, Frame

First of all, check out our newest video of our progress on the nosecone:

We have now started to shape with more than just a hot wire.  Looks like we’ll have a nosecone in no time!

Kudos to Josh and Alec for being composites gurus!

Build Progress, Composites

We made a carbon/kevlar intake and plenum and mounted it on our engine dyno.  Check it out:

Build Progress, Composites, Engine

Hi All,

We have put together the nosecone mold and have started to trim it down.  Below are the start and finish of the rough cutting of the mold foam:

In between the foam pieces is the laser cut wood from the video in the post below.  Stay tuned for more updates as we make our nosecone!

Build Progress, Composites

The bodywork production is in full swing.  Wood has been lasered in house and foam has been bandsawed.

Next up will be shaping and body filling galore!  Keep a watch on our posts to see updates!

Ben

Build Progress

Hi Everyone,

It has been a while since our last update on the build progress.  Here’s the rundown:

1)  Dyno is up and running!  Tuning is in progress.  Tip to those running a 1 cylinder engine using a MoTeC ECU–there is a HUGE bug not allowing the engine to start.  You must switch to 4-cylinder mode.  Contact MoTeC or our captain, Alex Rehberg for more information

2)  Frame is still under construction with the rear now in production.  We had a large delay due to welder training, but now we have 2 very good welders who will be able to get the frame done quickly.

3)  Rear upright fabrication is complete.  See Picture Below:

4)  Bodywork design has been finalized and construction is in progress.  We also have an updated CAD assembly:

Build Progress

It has been a while since the last post, so we at Formula thought we would give a general update on progress of the new car.

Frame:  Center section fully fabricated and welded.  Front fully fabricated and tack welded.  Rear designed

Suspension:  Rear Uprights designed, CAM Completed.

Composites:  Proof of concept for new body work complete.

Engine:  Engine dyno is nearing completion.  Wiring and sensor debugging is now in full swing

Please take a look at our Newsletter for more in-depth information on what has been going on this quarter.

Build Progress

We have not made a peep on the site in week, but I assure you we have been working on the design of our 2009 vehicle. Our previous (and first ever) race car was completed by six undergraduate students in 2008 in time for competition in May. For those of you familiar with the Formula SAE competition, it was basic stuff, spec-wise. we tried to keep it simple and reliable:

• TIG welded 4130 chrome-moly tubular space frame
• Non-parallel A-arm, double wishbone suspension
• Inboard mounted springs and adjustable dampers

• Suzuki LTR-450, 450cc single cylinder, fuel injected, DOHC engine
• Megasquirt ECU, custom tuned
• 5 speed manual sequential transmission with limited slip differential
• Goodyear D2692 20.0 x 7.0 13.0 racing slick tires

From left: Kyle, Drew, Grant

For 2009, we have begun several projects. I am leading a team to design and test a part of the chassis out of cored carbon fiber panels. I won’t say much more because we are in the middle of designing the tests and perfecting fabrication methods.

David, team manager and engine lead, is developing a flow bench and engine dynomometer for engine tuning. Our 2008 car had limited access to the tools and resources necessary, so we are developing our own.

There are a few other designs being developed as well (Drew designing suspension; Kyle, improving our 2008 car) and they will post when there is noteworthy progress to report.

Build Progress