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We milled the firewall directly into the part to save weight. We made all parts do "double duty" where ever we could.
http://www.clubcobra.com/photopost/d...ium/book72.jpg |
The top of the footbox was quite complicated. Everything was laid out in CAD. I am amazed at how perfectly everything fit together when we were done.
http://www.clubcobra.com/photopost/d...ium/book73.jpg |
The front of the footboxes were made from 1/2" plate to make them stiff. The footboxes had to carry the loads between the front and rear suspension.
http://www.clubcobra.com/photopost/d...ium/book74.jpg |
The upper picture shows prototype cowl structure. Notice the firewall was not milled directly into the part. After riveting a sheet of aluminum onto the part I told myself, "This is dumb!" So, we machined the "sheet metal" right into the part on the next iteration. In the lower photo, the number "77" in blue magic marker shows how many holes had to be tapped and drilled into the driver front plate in the footbox. 9 different surfaces had to be thought about while making the part.
http://www.clubcobra.com/photopost/d...ium/book75.jpg |
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A CAD program and a water jet can make some really cool parts!
http://www.clubcobra.com/photopost/d...ium/book79.jpg |
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A look at the Aerogel insulation. You can see the polished stainless heat shield on the engine side of the footbox.
http://www.clubcobra.com/photopost/d...ium/book81.jpg |
Here is a better shot of the stainless heat shield on top of the Aeorgel.
http://www.clubcobra.com/photopost/d...ium/book82.jpg |
In this closeup you can see the insulating sandwich we made. First line of defense, gold foil. The gold foil reflects 80% of the radiated heat from the pipes. Next, polished stainless steel heat shields. Stainless has the lowest coefficient of thermal transfer (heat takes a LONG time transfer from one end to the next) of any common metal. Next, Aerogel. Aerogel has THE lowest coefficient of thermal transfer of any known material. During testing the interior was absolutely cool. No heat at all came through to the interior.
http://www.clubcobra.com/photopost/d...ium/book83.jpg |
I'll post more as I can!
Happy to answer any questions! David :):):) |
I liked this quote because most people don't realize how much work actually goes into a project like this.
http://www.clubcobra.com/photopost/d...ium/book84.jpg |
I really liked this pic showing how we tried to make the undercarriage as smooth as possible.
http://www.clubcobra.com/photopost/d...ium/book85.jpg |
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Here is the next chapter. I'll work on machining as soon as I can get to it.
http://www.clubcobra.com/photopost/d...ium/book90.jpg |
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